Flame retardant and smoke suppressant composite high performance support-separators and conduit tubes

ABSTRACT

The present invention includes a high performance communications cable exhibiting reduced cross-talk of any form between transmission media that includes one or more core support-separators having various shaped profiles which define a clearance to maintain a spacing between transmission media or transmission media pairs. The core may be formed of a conductive or insulative material to further reduce cross-talk and improve other electrical properties as well as reduce flame and smoke spread. The cable and separators are comprised of principally polymer blends that include olefin and/or fluoropolymer and/or chlorofluoropolymer based resins with and without inorganic additive such as nano-clay composites. These unique blends offer both flame and smoke suppression while maintaining the characteristics necessary to improve electrical performance and allow for severe cost reduction over conventional separators. The specially shaped core support-separators can be either interior to the cable jacket or be employed singularly without the benefit of a jacket and extend along the longitudinal length of the communications cable. Alternatively, with no jacket for cable completion, a portion of the separator wherein a thin layer of material can act as a type of skin for future mechanical protection is provided. The specially shaped core support-separator has both a central region as well as a plurality of shaped sections that extend outward from the central region that are either solid or partially solid, foamed or foamed with a solid skin surface. In addition, the invention includes the optional incorporation of hollow ducts that can be used to provide optical or metal conductor media either before, during, or after installation of the cable primarily by gas driven means.

CLAIM TO PRIORITY

This utility application is based on provisional application No.60/534,646 filed Jan. 7, 2004 entitled “FLAME RETARDANT AND SMOKESUPPRESSANT COMPOSITE HIGH PERFORMANCE SUPPORT-SEPARATORS AND CONDUITTUBES” the contents of which are expressly incorporated by reference.

FIELD OF INVENTION

This invention relates to high performance multi-media communicationscables utilizing paired or unpaired electrical conductors or opticalfibers that meet stringent flame and smoke suppressant requirements bothin the United States under the National Electric Code (NEC) andinternationally through the guidelines established by the InternationalElectrotechnical Commission (IEC). More particularly, it relates tocables having a central core defining individual conductor pairchannels. The communications cables have interior coresupport-separators that define a clearance through which conductors oroptical fibers may be disposed and these separators are the subject ofthe present invention. The invention also pertains to conduit tubes thatcould be used in conjunction with or separately from the separators withthe defined clearance channels. These conduit tubes may be round,square, rectangular, elliptical or in any feasible geometric shape thatwould allow for any communications media conductor to be placed orsubsequently blown into place along the length of these tubes.Additionally and concurrently, the present invention relates tocomposite electrical insulation exhibiting reduced flame spread andreduced smoke evolution, while maintaining favorable electricalproperties within the conductors and cables. The present invention alsorelates to insulated electrical conductors and jacketed plenum cableformed from the flame retardant and smoke suppressant compositeinsulation(s).

BACKGROUND OF THE INVENTION

Many communication systems utilize high performance cables normallyhaving four pairs or more that typically consist of two twisted pairstransmitting data and two receiving data as well as the possibility offour or more pairs multiplexing in both directions. A twisted pair is apair of conductors twisted about each other. A transmitting twisted pairand a receiving twisted pair often form a subgroup in a cable havingfour twisted pairs. High-speed data communications media in currentusage includes pairs of wire twisted together to form a balancedtransmission line. Optical fiber cables may include such twisted pairsor replace them altogether with optical transmission media (fiberoptics).

When twisted pairs are closely placed, such as in a communicationscable, electrical energy may be transferred from one pair of a cable toanother. Energy transferred between conductor pairs is undesirable andreferred to as crosstalk. The Telecommunications Industry Associationand Electronics Industry Association have define standards forcrosstalk, including TIA/EIA-568 A, B, and C including the most recentedition of the specification. The International ElectrotechnicalCommission has also defined standards for data communication cablecrosstalk, including ISO/IEC 11801. One high-performance standard for100 MHz cable is ISO/IEC 11801, Category 5. Additionally, more stringentstandards are being implemented for higher frequency cables includingCategory 6 and Category 7, which includes frequencies of 200 and 600MHz, respectively and the most recent proposed industrial standardraising the speeds to 10 Gbit over copper with Ethernet or other cabledesigns. Industry standards cable specifications and known commerciallyavailable products are listed in Table 1 and a set of updated standardsfor Category 6, including alien crosstalk proposals are included inTables 2 A–G.

TABLE 1 INDUSTRY STANDARD CABLE SPECIFICATIONS TIA CAT 6 ANIXTER XP6ANIXTER XP7 ALL DATA AT DRAFT 10 R3.00XP R3.00XP 100 MHz TIA CAT 5e Nov.15, 2001 11/00 11/00 MAX TEST 100 MHz 250 MHz 250 MHz 350 MHz FREQUENCYATTENTUATION 22.0 db 19.8 db 21.7 db 19.7 db POWER SUM 32.3 db 42.3 db34.3 db 44.3 db NEXT ACR 13.3 db 24.5 db POWER SUM 10.3 db 22.5 db 12.6db 23.6 db ACR POWER SUM 20.8 db 24.8 db 23.8 db 25.8 db ELFEXT RETURNLOSS 20.1 db 20.1 db 21.5 db 22.5 db

TABLE 2A Return Loss Requirements for Category 6 Cable Return loss @ 20°C. ± 3° C. (68° F. ± 5.5° F.), worst pair for a length of 100 m (328 ft)Frequency MHz Category 6 dB  1 ≦ f ≦ 10 20 + 5 log (f) 10 ≦ f ≦ 20 25 20 ≦ f ≦ 250 25 − 7 log (f/20)

TABLE 2B Insertion Loss Requirements for Category 6 Cable Insertion loss@ 20° C. ± 3° C. (68° F. ± 5.5° F.), worst pair for a length of 100 m(328 ft) Frequency MHz Category 6 dB .772 1.8 10.0 6.0 250.0 32.8

TABLE 2C Near End Crosstalk Requirements For Category 6 Cable Horizontalcable NEXT loss @ 20° C. ± 3° C. (68° F. ± 5.5° F.), worst pair-to-pair,for a length of 100 m (328 ft) Frequency MHz Category 6 dB 0.150 86.710.0 59.3 250.0 38.3

TABLE 2D Power Sum Near End Crosstalk Requirements for Category 6 CablePSNEXT loss @ 20° C. ± 3° C. (68° F. ± 5.5° F.), for a length of 100 m(328 ft) Frequency MHz Category 6 dB 0.150 84.7 10.0 57.3 250.0 36.3

TABLE 2E Equal Level Near End Crosstalk Requirements for Category 6Cable ELNEXT loss @ 20° C. ± 3° C. (68° F. ± 5.5° F.), worstpair-to-pair for a length of 100 m (328 ft) Frequency MHz Category 6 dB.772 70.0 10.0 47.8 250.0 19.8

TABLE 2F Power Sum Equal Level Near End Crosstalk Requirements forCategory 6 Cable PSELNEXT loss @ 20° C. ± 3° C. (68° F. ± 5.5° F.), fora length of 100 m (328 ft) Frequency MHz Category 6 dB .772 67.0 10.044.8 250.0 16.8

TABLE 2G Proposed Requirements for Alien Near-end Cross-talk forCategory 6 Cable Proposed Requirement for Channel Power Sum AlienNear-End Cross-talk Frequency Category 6 dB PSANEXT ≧ 60 − 10log(f)  1 ≦f ≦ 100 MHz PSANEXT ≧ 60 − 15log(f) 100 ≦ f ≦ 625 MHz

In conventional cable, each twisted pair of conductors for a cable has aspecified distance between twists along the longitudinal direction. Thatdistance is referred to as the pair lay. When adjacent twisted pairshave the same pair lay and/or twist direction, they tend to lie within acable more closely spaced than when they have different pair lays and/ortwist direction. Such close spacing increases the amount of undesirablecross-talk that occurs. Therefore, in many conventional cables, eachtwisted pair within the cable has a unique pair lay in order to increasethe spacing between pairs and thereby to reduce the cross-talk betweentwisted pairs of a cable. Twist direction may also be varied. Along withvarying pair lays and twist directions, individual solid metal or wovenmetal air shields can be used to electro-magnetically isolate pairs fromeach other or isolate the pairs from the cable jacket.

Shielded cable, although exhibiting better cross-talk isolation, is moredifficult, time consuming and costly to manufacture, install, andterminate. Individually shielded pairs must generally be terminatedusing special tools, devices and techniques adapted for the job, alsoincreasing cost and difficulty.

One popular cable type meeting the above specifications is UnshieldedTwisted Pair (UTP) cable. Because it does not include shielded pairs,UTP is preferred by installers and others associated with wiringbuilding premises, as it is easily installed and terminated. However,UTP fails to achieve superior cross-talk isolation such as required bythe evolving higher frequency standards for data and other state of theart transmission cable systems, even when varying pair lays are used.

Some cables have used supports in connection with twisted pairs. Thesecables, however, suggest using a standard “X”, or “+” shaped support,hereinafter both referred to as the “X” support. Protrusions may extendfrom the standard “X” support. The protrusions of these prior inventionshave exhibited substantially parallel sides.

The document, U.S. Pat. No. 3,819,443, hereby incorporated by reference,describes a shielding member comprising laminated strips of metal andplastics material that are cut, bent, and assembled together to defineradial branches on said member. It also describes a cable including aset of conductors arranged in pairs, said shielding member and aninsulative outer sheath around the set of conductors. In this cable theshielding member with the radial branches compartmentalizes the interiorof the cable. The various pairs of the cable are therefore separatedfrom each other, but each is only partially shielded, which is not soeffective as shielding around each pair and is not always satisfactory.

The solution to the problem of twisted pairs lying too closely togetherwithin a cable is embodied in three U.S. Pat. Nos. 6,150,612 toPrestolite, 5,952,615 to Filotex, and 5,969,295 to CommScopeincorporated by reference herein, as well as an earlier similar designof a cable manufactured by Belden Wire & Cable Company as product number1711A. The prongs or splines in the Belden cable provide superior crushresistance to the protrusions of the standard “X” support. The superiorcrush resistance better preserves the geometry of the pairs relatives toeach other and of the pairs relative to the other parts of the cablessuch as the shield. In addition, the prongs or splines in this inventionpreferably have a pointed or slightly rounded apex top which easilyaccommodates an overall shield. These cables include four or moretwisted pair media radially disposed about a “+”-shaped core. Eachtwisted pair nests between two fins of the “+”-shaped core, beingseparated from adjacent twisted pairs by the core. This helps reduce andstabilize crosstalk between the twisted pair media. U.S. Pat. No.5,789,711 to Belden describes a “star” separator that accomplishes muchof what has been described above and is also herein incorporated byreference.

However, these core types can add substantial cost to the cable, as wellas excess material mass which forms a potential fire hazard, asexplained below, while achieving a crosstalk reduction of typically 3 dBor more. This crosstalk value is based on a cable comprised of afluorinated ethylene-propylene (FEP) conductors with PVC jackets as wellas cables constructed of FEP jackets with FEP insulated conductors.Cables where no separation between pairs exist will exhibit smallercross-talk values. When pairs are allowed to shift based on “free space”within the confines of the cable jacket, the fact that the pairs may“float” within a free space can reduce overall attenuation values due tothe ability to use a larger conductor to maintain 100 ohm impedance. Thetrade-off with allowing the pairs to float is that the pair ofconductors tend to separate slightly and randomly. This undesirableseparation contributes to increased structural return loss (SRL) andmore variation in impedance. One method to overcome this undesirabletrait is to twist the conductor pairs with a very tight lay. This methodhas been proven impractical because such tight lays are expensive andgreatly limits the cable manufacturer's throughput and overallproduction yield. An improvement included by the present invention tostructural return loss and improved attenuation is to provide grooveswithin channels for conductor pairs such that the pairs are fixedlyadhered to the walls of these grooves or at least forced within aconfined space to prevent floating simply by geometric configuration.This configuration is both described here within and referenced in U.S.Pat. No. 6,639,152 filed Aug. 25, 2001 as well as PCT/US02/13831 filedat the United States Patent and Trademark Office on May 1, 2002.

A “rifling” or “ladder-like” separator design also contributes toimproved attenuation, power sum NEXT (near end cross talk), power sumACR (attenuation cross-talk ratio) and ELFEXT (equal level far endcross-talk) by providing for better control of spacing of the pairs,adding more air-space, and allowing for “pair-twinning” at differentlengths. Additional benefits include reduction of the overall materialmass required for conventional spacers, which contributes to flame andsmoke reduction.

In building designs, many precautions are taken to resist the spread offlame and the generation of and spread of smoke throughout a building incase of an outbreak of fire. Clearly, the cable is designed to protectagainst loss of life and also minimize the costs of a fire due to thedestruction of electrical and other equipment. Therefore, wires andcables for building installations are required to comply with thevarious flammability requirements of the National Electrical Code (NEC)in the U.S. as well as International Electrotechnical Commission (EIC)and/or the Canadian Electrical Code (CEC).

A broad range of electrical conductors and electrical cables areinstalled in modern buildings for a wide variety of uses. Such usesinclude data transmission between computers, voice communications, aswell as control signal transmission for building security, fire alarm,and temperature control systems. These cable networks extend throughoutmodern office and industrial buildings, and frequently extend throughthe space between the dropped ceiling and the floor above. Ventilationsystem components are also frequently extended through this space fordirecting heated and chilled air to the space below the ceiling and alsoto direct return air exchange. The space between the dropped ceiling andthe floor above is commonly referred to as the plenum area. Electricalconductors and cables extending through plenum areas are governed byspecial provisions of the National Electric Code (“NEC”).

Cables intended for installation in the air handling spaces (i.e.plenums, ducts, etc.) of buildings are specifically required byNEC/CEC/IEC to pass the flame test specified by UnderwritersLaboratories Inc. (UL), UL-910, or its Canadian Standards Association(CSA) equivalent, the FT6. The UL-910, FT-6, and the NFPA 262 representthe top of the fire rating hierarchy established by the NEC and CECrespectively. Also important are the UL 1666 Riser test and the IEC60332-3C and D flammability criteria. Cables possessing these ratings,generically known as “plenum” or “plenum rated” or “riser” or “riserrated”, may be substituted for cables having a lower rating (i.e. CMR,CM, CMX, FT4, FTI or their equivalents), while lower rated cables maynot be used where plenum or riser rated cables are required.

In 1975, the NFPA recognized the potential flame and smoke hazardscreated by burning cables in plenum areas, and adopted in the NEC astandard for flame retardant and smoke suppressant cables. Thisstandard, commonly referred to as “the Plenum Cable Standard”, permitsthe use of cable without conduit, so long as the cable exhibits lowsmoke and flame retardant characteristics. The test method for measuringthese characteristics is commonly referred to as the Steiner TunnelTest. The Steiner Tunnel Test has been adapted for the burning of cablesaccording to the following test protocols: NFPA 262, UnderwritersLaboratories (U.L.) 910, or Canadian Standards Association (CSA) FT-6.The test conditions for each of the U.L. 910 Steiner Tunnel Test, CSAFT-6, and NFPA 262 are as follows: a 300,000 BTU/hour flame is appliedfor 20 minutes to ten 24-foot lengths of test cables mounted on ahorizontal tray within a tunnel. The criteria for passing the SteinerTunnel Test are as follows:

A. Flame spread—flame travel less than 5.0 feet.

B. Smoke Generation:

1. Maximum optical density of smoke less than 0.5.

2. Average optical density of smoke less than 0.15.

Because of concerns that flame and smoke could travel along the extentof a plenum area in the event the electrical conductors and cable wereinvolved in a fire, the National Fire Protection Association (“NFPA”)has developed a standard to reduce the amount of flammable materialincorporated into insulated electrical conductors and jacketed cables.Reducing the amount of flammable material would, according to the NFPA,diminish the potential of the insulating and jacket materials fromspreading flames and evolving smoke to adjacent plenum areas andpotentially to more distant and widespread areas throughout a building.

The products of the present invention have also been developed tosupport the evolving NFPA standard referenced as NFPA 255 entitled“Limited Combustible Cables” with less than 50 as a maximum smoke indexand/or NFPA 259 entitled “Heat of Combustion” which includes the use ofan oxygen bomb calorimeter that allows for materials with less than 3500BTU/lb. for incorporation into the newer cable (and conductors andseparators within these cables) designs. The proposed materials of thepresent invention are for inclusion with high performance supportseparators and conduit tubes designed to meet the new and evolvingstandards proposed for National Electrical Code (NEC) adoption in 2005.Table 4 below provides the specific requirements for each of the

Cables conforming to NEC/CEC/IEC requirements are characterized aspossessing superior resistance to ignitability, greater resistant tocontribute to flame spread and generate lower levels of smoke duringfires than cables having lower fire ratings. Often these properties canbe anticipated by the use of measuring a Limiting Oxygen Index (LOI) forspecific materials used to construct the cable. Conventional designs ofdata grade telecommunication cable for installations in plenum chambershave a low smoke generating jacket material, e.g. of a specially filledPVC formulation or a fluoropolymer material, surrounding a core oftwisted conductor pairs, each conductor individually insulated with afluorinated insulation layer. Cable produced as described abovesatisfies recognized plenum test requirements such as the “peak smoke”and “average smoke” requirements of the Underwriters Laboratories, Inc.,UL910 Steiner tunnel test and/or Canadian Standards Association CSA-FT6(Plenum Flame Test) while also achieving desired electrical performancein accordance with EIA/TIA-568 A, B, and C for high frequency signaltransmission.

The newer standards are forcing industrial “norms” to change andtherefore require a new and unique set of materials that will berequired to achieve new standards. These materials are the subject ofthe present invention and include nano-composites of clay and otherinorganics such as ZnO and TiO₂ both also as nano-sized particles. Inaddition, the use of insulative or semi-conductive Buckminsterfullerenes and doped fullerenes of the C₆₀ family and the like are partof the present invention and offer unique properties that allow formaintaining electrical integrity as well as providing the necessaryreduction in flame retardance and smoke suppression.

While the above described conventional cable, due in part to their useof fluorinated polymers, meets all of the above design criteria, the useof fluorinated polymers is extremely expensive and may account for up to60% of the cost of a cable designed for plenum usage. A solid core ofthese communications cables contributes a large volume of fuel to apotential cable fire. Forming the core of a fire resistant material,such as with FEP (fluorinated ethylene-propylene), is very costly due tothe volume of material used in the core, but it should help reduce flamespread over the 20 minute test period. Reducing the mass of material byredesigning the core and separators within the core is another method ofreducing fuel and thereby reducing smoke generation and flame spread.For the commercial market in Europe, low smoke fire retardant polyolefinmaterials have been developed that will pass the EN (European Norm)502666-Z-X Class B relative to flame spread, total heat release, relatedheat release, and fire growth rate. Prior to this inventive development,standard cable constructions requiring the use of the aforementionedexpensive fluorinated polymers, such as FEP, would be needed to passthis rigorous test. Using low smoke fire retardant polyolefins forspecially designed separators used in cables that meet the morestringent electrical requirements for Categories 6 and 7 and also passthe new norm for flammability and smoke generation is a further subjectof this invention. Tables 3A, 3B, and 4 indicates categories for flameand smoke characteristics and associated test methods as discussedabove.

TABLE 3A International Classification and Flame Test Methodology forCommunications Cable Additional Class Test Methods ClassificationCriteria Classification A_(ca) EN ISO 1716 PCS ≦ 2.0 MJ/kg (1) and PCS ≦2.0 MJ/kg (2) B_(1ca) FIPEC₂₀ Scenario 2 (6) FS ≦ 1.75 m and Smokeproduction (3, 7) and THR₁₂₀₀ ≦ 10 MJ and and Flaming Peak HRR ≦ 20 kWand droplets/particles (4) FIGRA ≦ 120 Ws⁻¹ and Acidity (5) EN 50285-2-1H ≦ 425 mm B_(2ca) FIPEC₂₀ Scenario 1 (6) FS ≦ 1.5 m and Smokeproduction (3, 8) and THR₁₂₀₀ ≦ 15 MJ and and Flaming Peak HRR ≦ 30 kWand droplets/particles (4) FIGRA ≦ 150 Ws⁻¹ and Acidity (5) EN 50285-2-1H ≦ 425 mm C_(ca) FIPEC₂₀ Scenario 1 (6) FS ≦ 2.0 m and Smoke production(3, 8) and THR₁₂₀₀ ≦ 30 MJ and and Flaming Peak HRR ≦ 60 kW anddroplets/particles (4) FIGRA ≦ 300 Ws⁻¹ and Acidity (5) EN 50285-2-1 H ≦425 mm D_(ca) FIPEC₂₀ Scenario 1 (6) THR₁₂₀₀ ≦ 70 MJ and Smokeproduction (3, 8) and Peak HRR ≦ 400 kW and and Flaming FIGRA ≦ 1300Ws⁻¹ droplets/particles (4) and Acidity (5) EN 50285-2-1 H ≦ 425 mm EcaEN 50285-2-1 H ≦ 425 mm Acidity (5) Fca No Performance Determined (1)For the product as a whole, excluding metallic materials. (2) For anyexternal component (ie. Sheath) of the product. (3) S1 = TSP₁₂₀₀ ≦ 50 M²and peak SPR ≦ 0.25 m²/s S2 = TSP₁₂₀₀ ≦ 400 M² and peak SPR ≦ 1.5 m²/sS3 = Not S1 or S2 (4) For FIPEC₂₀ Scenarios 1 and 2: d0 = No flamingdroplets/particles within 1200 s d1 = No flaming droplets/particlespersisting longer than 10 s within 1200 s d3 = not d0 or d1 (5) EN50285-2-1: (?) A1 = conductivity < 2.5 μS/mm and pH > 4.3 A2 =conductivity < 10 μS/mm and pH > 4.3 A3 = not A1 or A2 No declaration =No Performance Determined (6) Airflow into chamber shall be set to 8000+/− 800 l/min. FIPEC₂₀ Scen.1 = prEN50399-2-1 with mounting and fixingaccording to Annex 2 FIPEC₂₀ Scen.2 = prEN50399-2-2 with mounting andfixing according to Annex 2 (7) The smoke class declared in class B1cacables must originate from the FIPEC₂₀ Scen.2 test (8) The smoke classdeclared in class B2ca cables must originate from the FIPEC₂₀ Scen.1test

TABLE 3B International Classification and Test Methodology forCommunications Cable Pending CPD Euro-Classes for Cables PCS = grosscalorific potential FIGRA = fire growth rate FS = flame spread TSP =total smoke production (damaged length) THR = total heat release SPR =smoke production rate HRR = heat release rate H = flame spread PendingCPD Euro-Classes for Communications & Energy Cables [A1] EN ISO 1716Mineral Filled Circuit Integrity Cables [B1] FIPEC Sc.2/EN 50265-2-1LCC/HIFT - type LAN Comm. Cables [B2] FIPEC Sc.1/EN 50265-2-1 EnergyCables [C] FIPEC Sc.1/EN 50265-2-1 High FR/Riser-type Cables [D] FIPECSc.1/EN 50265-2-1 IEC 332.3C type Cables [E] EN 50265-2-1 IEC 332.1/VW1type Cables [F] No Requirement

TABLE 4 Flammability Test Methods and Level of Severity for Wire andCable Test Method Ignition Source Output Airflow Duration UL2424/NFPA  8 MJ/kg — — 259/255/UL723 (35,000 BTU/lb.) Steiner Tunnel   88 kW (300k BTU/hr.) 73 m/min. 20 min. UL 910/NFPA 262 (240 ft/min.) forced RISER 154 kW (527 K BTU/hr.) Draft 30 min. UL2424/NFPA 259 Single BurningItem   30 kW (102 k BTU/hr.) 36 m³/min. 30 min. (20 min burner) ModifiedIEC 60332-3   30 kW (102 k BTU/hr.)  8 m³/min. 20 min. (Backboard behindladder (heat impact)) IEC 60332-3 20.5 kW (70 k BTU/hr.)  5 m³/min. 20min Vertical Tray 20.5 kW (70 k BTU/hr.) Draft 20 min IEC 60332-1/ULVW-1Bunsen Burner —  1 min (15 sec. Flame) Evolution of Fire Performance(Severity Levels) VW 1/IEC 60332-1/FT-1/CPD Class E (least severe) UL1581 Tray/IEC 60332-3/FT-2/CPD Class D ↓ UL 1666 Riser/FT-4/CPD Class C& B2 ↓ NFPA 262/EN 50289/FT-6/CPD Class B1/UL 910 ↓ NFPA 255 & NFPA259/LC/CPD Class B1+/UL 2424 (most severe)

Table 5 indicates requirements for wire and cable that can meet some ofthe test method criteria as provided in Table 4. “Low smoke and flamecompound A” is a fluoropolymer based blend that includes inorganicsknown to provide proper material properties such that NFPA 255 and NFPA259 test protocols may be met.

TABLE 5 Material Requirements and Properties for Plenum, Riser, andHalogen Free Cables Low Smoke and Flame Compound A LSFR PVC (HalogenFree) (Halogen Free) NFPA 255/259 HIFT/NFPA 262 IEC 332.2C IEC 332.1Properties LC Euro Class B1 Class C/D Euro Class E Specific 2.77 g/cc1.65 g/cc 1.61 g/cc 1.53 g/cc Gravity Durometer 69/61 72/63 59/49 53/47D Aged, Inst/15 sec. Tensile 2,250 psi/15.5 Mpa 2,500 psi/ 1,750 psi/1,750 psi/ Strength, 17.2 Mpa 12.1 Mpa 12.1 Mpa 20″/min. Elongation,250% 180% 180% 170% 20″/min. Oxygen 100+%  53%  53%  35% Index, (0.125″)Brittle −46 −5 −22 −15 point, deg C. Flexural 202000 psi/1400 Mpa 56000psi/390 Mpa 41000 psi/280 Mpa 49000 psi/340 MPa Modulus, 0.03″/min. ULTemp 125+ 60   90   75 Rating, deg C. Dielectric  2.92  3.25    3.87   3.57 Constant, 100 MHz Dissipation  0.012  0.014    0.015    0.014Factor, 100 MHz 4pr UTP 9–11 mils/.23–.28 mm 15–17 mils/.38–.43 mm 30–40mils/.76–1.02 mm 20–24 mils/.50–.60 mm Jkt Thickness

Table 6 is provided as an indicator of low acid gas generationperformance for various materials currently available for producing wireand cable and cross-web designs of the present invention. The presentinvention includes special polymer blends that are designed tosignificantly reduce these values to levels to those shown for low smokeand flame Compound A listed above in Table 5.

TABLE 6 Acid Generation Values for Wire and Cable Insulation MaterialsMaterial % Acid PH FEP 27.18 1.72 ECTFE 23.890 1.64 PVDF 21.48 2.03 LSFRPVC 13.78 1.90 Low Smoke and Flame 1.54 3.01 Compound A 48% LOI HFFR0.35 3.42 34% LOI HFFR .024 3.94

Solid flame retardant/smoke suppressed polyolefins may also be used inconnection with fluorinated polymers. Commercially available solid flameretardant/smoke suppressed polyolefin compounds all possess dielectricproperties inferior to that of FEP and similar fluorinated polymers. Inaddition, they also exhibit inferior resistance to burning and generallyproduce more smoke than FEP under burning conditions. A combination ofthe two different polymer types can reduce costs while minimallysacrificing physio-chemical properties. An additional method that hasbeen used to improve both electrical and flammability propertiesincludes the irradiation of certain polymers that lend themselves tocrosslinking. Certain polyolefins are currently in development that haveproven capable of replacing fluoropolymers for passing these samestringent smoke and flammability tests for cable separators, also knownas “cross-webs”. Additional advantages with the polyolefins arereduction in cost and toxicity effects as measured during and aftercombustion. The present invention utilizes blends of fluoropolymers withprimarily polyolefins as well as the use of “additives” that include C₆₀fullerenes and compounds that incorporate the fullerenes and substitutedfullerenes as well as inorganic clays and metal oxides as required forinsulative or semi-conductive properties in addition to the flame andsmoke suppression requirements. The use of fluoropolymer blends withother than polyolefins is also a part of the present invention and theincorporation of these other “additives” will be included as the newcompounds are created. Reduction of acid gas generation is another keyfeature provided by the use of these blends as shown in Table 6 andanother important advantage presented in the use of the cables andseparators of the present invention. Price and performancecharacteristics for the separators and conduit tubes will determine theexact blend ratios necessary for these compounds.

A high performance communications data cable utilizing twisted pairtechnology must meet exacting specification with regard to data speed,electrical, as well as flammability and smoke characteristics. Theelectrical characteristics include specifically the ability to controlimpedance, near-end cross-talk (NEXT), ACR (attenuation cross-talkratio) and shield transfer impedance. A method used for twisted pairdata cables that has been tried to meet the electrical characteristics,such as controlled NEXT, is by utilizing individually shielded twistedpairs (ISTP). These shields insulate each pair from NEXT. Data cableshave also used very complex lay techniques to cancel E and B (electricand magnetic fields) to control NEXT. In addition, previouslymanufactured data cables have been designed to meet ACR requirements byutilizing very low dielectric constant insulation materials. Use of theabove techniques to control electrical characteristics have inherentproblems that have lead to various cable methods and designs to overcomethese problems. The blends of the present invention are designed suchthat these key parameters can be met.

Recently, as indicated in Tables 1, 2A and 2B, the development of“high-end” electrical properties for Category 6 and 7 cables hasincreased the need to determine and include power sum NEXT (near endcrosstalk) and power sum ELFEXT (equal level far end crosstalk)considerations along with attenuation, impedance, and ACR values. Thesedevelopments have necessitated the development of more highly evolvedseparators that can provide offsetting of the electrical conductor pairsso that the lesser performing electrical pairs can be further separatedfrom other pairs within the overall cable construction.

Recent and proposed cable standards are increasing cable maximumfrequencies from 100–200 MHz to 250–700 Mhz. Recently, 10 Gbit overcopper high speed standards have been proposed. The maximum upperfrequency of a cable is that frequency at which the ACR(attenuation/cross-talk ratio) is essentially equal to 1. Sinceattenuation increases with frequency and cross-talk decreases withfrequency, the cable designer must be innovative in designing a cablewith sufficiently high cross-talk. This is especially true since manyconventional design concepts, fillers, and spacers may not providesufficient cross-talk at the higher frequencies. Proposed limits foralien crosstalk have also been added to the present standards as shownin Table 2G. Such limits in many cases can only be met using theseparators of the present invention.

Current separator designs must also meet the UL 910 flame and smokecriteria using both fluorinated and non-fluorinated jackets as well asfluorinated and non-fluorinated insulation materials for the conductorsof these cable constructions. In Europe, the trend continues to be useof halogen free insulation for all components, which also must meetstringent flammability regulations. The use of the blends of the presentinvention for both separators and tube conduits will allow for meetingthese requirements.

In plenum applications for voice and data transmission, electricalconductors and cables should exhibit low smoke evolution, low flamespread, and favorable electrical properties. Materials are generallyselected for plenum applications such that they exhibit a balance offavorable and unfavorable properties. In this regard, each commonlyemployed material has a unique combination of desirable characteristicsand practical limitations. Without regard to flame retardancy and smokesuppressant characteristics, olefin polymers, such as polyethylene andpolypropylene, are melt extrudable thermoplastic materials havingfavorable electrical properties as manifested by their very lowdielectric constant and low dissipation factor.

Dielectric constant is the property of an insulation material whichdetermines the amount of electrostatic energy stored per unit potentialgradient. Dielectric constant is normally expressed as a ratio. Thedielectric constant of air is 1.0, while the dielectric constant forpolyethylene is 2.2. Thus, the capacitance of polyethylene is 2.2 timesthat of air. Dielectric constant is also referred to as the SpecificInductive Capacity or Permittivity.

Dissipation factor refers to the energy lost when voltage is appliedacross an insulation material, and is the contangent of the phase anglebetween the voltage and current in a reactive component. Dissipationfactor is quite sensitive to contamination of an insulation material.Dissipation factor is also referred to as the Power Factor (ofdielectrics).

Fluorinated ethylene/propylene polymers exhibit electrical performancecomparable to non-halogenated to olefin polymers, such as polyethylene,but are over 15 times more expensive per pound. Polyethylene also hasfavorable mechanical properties as a cable jacket as manifested by itstensile strength and elongation to break. However, polyethylene exhibitsunfavorable flame and smoke characteristics.

Limiting Oxygen Index (ASTM D-2863) (“LOI”) is a test method fordetermining the percent concentration of oxygen that will supportflaming combustion of a test material. The greater the LOI, the lesssusceptible a material is to burning. In the atmosphere, there isapproximately 21% oxygen, and therefore a material exhibiting an LOI of22% or more cannot burn under ambient conditions. As pure polymerswithout flame retardant additives, members of the olefin family, namely,polyethylene and polypropylene, have an LOI of approximately 19. Becausetheir LOI is less than 21, these olefins exhibit disadvantageousproperties relative to flame retardancy in that they do notself-extinguish flame, but propagate flame with a high rate of heatrelease. Moreover, the burning melt drips on the surrounding areas,thereby further propagating the flame.

In the U.S. and Canada, the standards for flame retardancy for voicecommunication and data communication cables are stringent. The plenumcable test (U.L. 910/CSA FT-6) and riser cable test U.L. 1666 aresignificantly more stringent than the predominantly used Internationalfire test IEC 332-3, which is similar to the IEEE 383/U.L. 1581 test.Table 4 already summarizes the standards required for various U.L.(Underwriters Laboratories and CSA (Canadian Standards Authority) cabledesignations.

As indicated above, current separator designs must also meet the UL 910flame and smoke criteria using both fluorinated and non-fluorinatedjackets as well as fluorinated and non-fluorinated insulation materialsfor the conductors of these cable constructions. The UL 910 criteria hasbeen included in the recently adopted NFPA 262 criteria and extendedwith more severity in the NFPA 255 and 259 test criteria. To ensure thatthe test criteria is met, the use of the separators of the currentinvention is not only useful but often necessary. For meeting the NFPA72 test criteria for circuit integrity cable, the support-separators andthe materials from which they will be produced is an integral part ofthe present invention. The reduction in material loading (lbs/MFT) asshown in Table 7 can be an essential aspect in meeting this demand.Substantial reduction of this load by the use of separators can beachieved. The use of the polymer blends of the present invention forboth separators and conduit tubes will allow for meeting therequirements for not only current circuit integrity cables but also forcables that must meet the newer more stringent requirements in thefuture.

TABLE 7 Insulation Material Criteria For Circuit Integrity Cable JacketAp- Number Insulation Thick- Cable proximate Nominal of Con- AWGThickness ness Diameter Weight Cable Lay ductors size (mils) (mils) (in)(lbs/MFT) (in./twist) 2 16 35 40 .34 59 3.7 2 14 35 40 .36 75 4.0 2 1235 50 .42 106 4.4

Principal electrical criteria can be satisfied based upon the dielectricconstant and dissipation factor of an insulation or jacketing material.Secondarily, the electrical criteria can be satisfied by certain aspectsof the cable design such as, for example, the insulated twisted pair laylengths. Lay length, as it pertains to wire and cable, is the axialdistance required for one cabled conductor or conductor strand tocomplete one revolution about the axis of the cable. Tighter and/orshorter lay lengths generally improve electrical properties.

Individual shielding is costly and complex to process. Individualshielding is highly susceptible to geometric instability duringprocessing and use. In addition, the ground plane of individual shields,360° in ISTP's—individually shielded twisted pairs is also an expensiveprocess. Lay techniques and the associated multi-shaped anvils of thepresent invention to achieve such lay geometries are also complex,costly and susceptible to instability during processing and use. Anotherproblem with many data cables is their susceptibility to deformationduring manufacture and use. Deformation of the cable geometry, such asthe shield, also potentially severely reduces the electrical and opticalconsistency.

Optical fiber cables exhibits a separate set of needs that includeweight reduction (of the overall cable), optical functionality withoutchange in optical properties and mechanical integrity to prevent damageto glass fibers. For multi-media cable, i.e. cable that contains bothmetal conductors and optical fibers, the set of criteria is oftenincompatible. The use of the present invention, however, renders theseoften divergent set of criteria compatible. Specifically, optical fibersmust have sufficient volume in which the buffering and jacketing plenummaterials (FEP and the like) covering the inner glass fibers can expandand contract over a broad temperature range without restrictions, forexample −40 C to 80 C experienced during shipping. It has been shown byGrune, et. al., among others, that cyclical compression and expansiondirectly contacting the buffered glass fiber causes excess attenuationlight loss (as measured in dB) in the glass fiber. The design of thepresent invention allows for designation and placement of optical fibersin clearance channels provided by the support-separator having multipleshaped profiles. It would also be possible to place both glass fiber andmetal conductors in the same designated clearance channel if such adesign is required. In either case the forced spacing and separationfrom the cable jacket (or absence of a cable jacket) would eliminate theundesirable set of cyclical forces that cause excess attenuation lightloss. In addition, fragile optical fibers are susceptible to mechanicaldamage without crush resistant members (in addition to conventionaljacketing). The present invention addresses this problem by includingthe use of both organic and inorganic polymers as well as inorganiccompounds blended with fluoropolymers to achieve the necessaryproperties.

The need to improve the cable and cable separator design, reduce costs,and improve both flammability and electrical properties continues toexist.

OBJECTIVE OF THE INVENTION

An objective is to provide a high performance communications cable wherean interior support, a central region, and outwardly extended portionsand optional conduit tubes are capable of shielding conductors thattransmit data at 10 Gbit while substantially mitigating or eliminatingalien crosstalk.

An objective of the invention is a high performance communications cablewith an interior support, a central region, and outwardly extendedportions and optional conduit tubes that are comprised of organic blendsincluding homo and copolymers of ethylene or polyvinyl chloride withfluorinated ethylene propylene, fluorinated ethylene, chlorinatedethylene propylene, fluorochlorinated ethylene, perfluoroalkoxy,fluorochlorinated propylene, a copolymer of tetrafluoroethylene andperfluoromethylvinylether (MFE), a copolymer of ethylene andchlorotrifluoroethylene (ECTFE), as well as homo and copolymers ofethylene and/or propylene with fluorinated ethylene propylene,fluorinated ethylene, chlorinated ethylene propylene, fluorochlorinatedethylene, perfluoroalkoxy, fluorochlorinated propylene, as well asblends of polyvinyl chloride, polyvinylidene chloride, unsubstituted orsubstituted fullerenes primarily comprised of C₆₀ molecules, nylons,polyesters, polyurethanes; and nano-composites of clay including; andnano-sized particles of ZnO or TiO and the like.

Another objective is the high performance communications cable separatoror conduit tube where the interior support, the central region, andoutwardly extended portions and optional conduit tubes are comprised ofcompounds such as acid gas scavengers that scavenge gasses such ashydrogen chloride and hydrogen fluoride and other halogenated gasses.

Additionally, the high performance communications cable separator orconduit tube where the interior support, central region, and outwardlyextended portions and optional conduit tubes are comprised of a foamedpolymer blend ratio of halogenated polymers or copolymers to ethylene orvinyl chloride polymers or copolymers of from 0.1% to up to 99.9% of thehalogenated polymers to ethylene or vinyl chloride polymers orcopolymers and where the foam polymer blend includes a nucleating agentof polytetrafluoroethylene, carbon black, color concentrate or boronnitride or other acceptable nucleating or blowing agent.

Another objective is a high performance communications cable separatoror conduit tube comprising an interior support with an external radialand axial surface, extending along a longitudinal length of acommunications cable the interior support also having a central region,the central region also extending along a longitudinal length of theinterior support of the communications cable; the interior supportcomprising one or more outwardly extended shaped portions and optionalconduit tubes extended from the central region wherein the centralregion and outwardly extended portions are comprised of organic polymerblends.

Additionally, anvil-shaped core support-separator sections comprisechannel walls defining one or more clearance channels and where theclearance channels are defined by a semi-circular geometry such thatthere remains a 180 degree opening along the external radial and axialsurface of the interior support.

In addition, each anvil-shaped core support-separator sections comprisesclearance walls defined by a semi-closed semi-circular geometry suchthat there remains less than a 160 degree opening along the exteriorradial and axial surface, but more than a 10 degree opening along theexternal surface of the interior support of the clearance channels.

In another objective the flap-top is comprised of a press-fitarrangement that is hinged allowing for opening and closing the exteriorradial and axial surfaces of the channel walls of the clearancechannels.

Additionally the flap-top is sealed by use of heat, tape, interlocking,or by skin extrusion of the hinged press-fit arrangement.

An additional objective is anvil-shaped core support-separator sectionscomprising clearance walls defined by a fully closed circular geometrythat remain closed but optionally includes an interlocking doubleflap-top, where the double flap-top is adhered to or adjoined with asurface on each side of the clearance walls for opening or closing theexterior radial and axial surfaces of the channel walls of the clearancechannels.

Another objective is that the channel walls comprise interior surfacesthat are corrugated including internal axial grooves separated by asufficient distance such that individual conductors or conductor pairsmaintain required electrical integrity and such that the conductor orconductor pairs are forced against an edge of the grooves or sections ofthe channel walls.

In addition, the metal conductors are copper with or without metallicshielding or aluminum with or without metallic shielding.

Additionally, at least one anvil shaped support-separator sectioncomprises rounded edges at an outer radial end of the anvil shapedsections sufficient to reduce overall weight and size of thesupport-separator and subsequently the cable.

An additional objective is at least one anvil shaped support-separatorsections comprising minimized dual lobes at an outer radial end of themulti-anvil shaped sections sufficient to minimize and reduce overallweight and size of the support-separator and subsequently the cable.

Additionally the anvil shaped core support-separator sections themselvesare twisted to a specified lay length.

An additional objective is an interior support-separator for acommunications cable extending along a longitudinal length of acommunications cable comprising along the support-separator'scross-section a pendulum shaped configuration with two ends with apendant shaped section comprising triangular shaped pendants with apexesthat face in opposite directions along a horizontal plane in a centralregion of the pendulum shaped separator comprising a diamond-like shapeand an optional hollow orifice in a center region of the central portionof the interior support-separator.

Additionally the triangular shaped pendants may be nearer either end ofthe central region of the pendulum shaped separator than near thecentral region.

Another objective of the present disclosure is an interiorsupport-separator for a communications cable extending along alongitudinal length of a communications cable, comprising, along itscross-section, a dual-lobed shaped pendulum-like configuration withcurved elongated lobed end portions along a top portion and a bottomportion of the pendulum-like separator creating at least two clearancechannels for conductors or conductor pairs and an optional holloworifice in a center region of the central portion of the interiorsupport-separator.

In addition is an interior support-separator for a communications cableextending along a longitudinal length of a communications cable,comprising at least two symmetrical or asymmetrical intersecting armsthat intersect in a cross-like manner along an essentially horizontaland vertical axis; the intersecting arms provided with ladder-like stepsevenly spaced along each arm and along a complete length of the armwhereby each arm with the ladder-like steps forms a rifle-like patternalong the horizontal and vertical axes the intersecting arms providingfour or more separate clearance channels and the arms are comprised ofsolid or foamed material.

Another objective is an interior support-separator for a communicationscable extending along a longitudinal length of a communications cable,comprising at least two intersecting arms that intersect in a cross-likemanner along an essentially horizontal and vertical axis with theintersecting arms optionally providing ladder-like steps evenly spacedalong each arm and along a complete length of the arm whereby each armwith the ladder-like steps forms a rifle-like saw-tooth pattern alongthe horizontal and vertical axes and a central portion of theintersection of the arms, with the central portion comprising a solidpredetermined shaped member that includes step-like portions cut awayfrom the central solid member and an optional hollow orifice in a centerregion of the central portion of the interior support-separator wherethe central region is void of a saw-tooth member along at least one ormore of the horizontal and vertical axes.

Additionally is an interior support-separator for a communications cableextending along a longitudinal length of a communications cablecomprising at least two spatial quadrants defined by a horizontal armmember of a support including a two sided drill-bit-like shaped centralmember with geometrically symmetric sections in opposite quadrants and;each drill-bit-like shape a mirror image of the other drill-bit-likeshape in the other quadrant and the support in sum appears to be shapedas a mirrored battleship and an optional hollow orifice in a centerregion of the central portion of the interior support-separator.

Another objective is an interior support-separator for a communicationscable extending along a longitudinal length of a communications cable,comprising at least two intersecting arms that intersect in a cross-likemanner comprising a cross-like support separator along an essentiallyhorizontal and vertical axis; the intersecting arms optionally providedwith ladder-like steps evenly spaced along each arm and along a completelength of the arm whereby each arm with the ladder-like steps forms arifle-like saw-tooth pattern along the horizontal and vertical axes anda central portion of the intersection of the arms, with the centralportion comprising an optional hollow center wherein the vertical andhorizontal intersecting arms are initially wide or narrow along ahorizontal or vertical axis and become finally narrow or wide along thehorizontal or vertical axis such that the cross-like support separatorcomprises an asymmetric pattern.

Additionally an objective is an interior support-separator for acommunications cable extending along a longitudinal length of acommunications cable comprising at least two spatial quadrants definedby two horizontal members with two sides of the support connected by avertical member with two sides such that the complete support appears asa symmetric or skewed angle iron with a z-like shape and where each ofthe members may be longer, shorter or the same length as each of theother two members.

An additional objective of this disclosure is an interior supportproviding a specified lay length by implementing a twisting of theclearance channels thereby providing a lay length twist into thesupport-separator during manufacturing of the final communications cableassembly.

Additionally an objective is a high performance communications cablecomprising an interior support-separator with an external radial axialsurface extending along a longitudinal length of the communicationscable with the interior support also having a central region and thecentral region also extending along a longitudinal length of theinterior support and the communications cable. The cable comprises 24pair of electrical conductors and a twenty fifth pair of electricalconductors where the twenty fifth pair is placed within an orificewithin the central region of the interior support-separator.

An objective also is a high performance communications cable where theinterior support, the central region, and the outwardly extendedsections and optional conduit tubes comprise solid, partially solid, orfoamed organic or inorganic dielectric materials either solid orpartially solid, foamed or foamed with a solid skin surface.

An objective also is a high performance communications cable separatoror conduit tube where the interior support, the central region, and theoutwardly extended sections and optional conduit tubes comprise solid,partially solid, or foamed organic or inorganic dielectric materialseither solid or partially solid, foamed or foamed with a solid skinsurface.

Additionally, there is an objective of a the high performancecommunications cable where the interior support, the central region andthe anvil shaped core support-separator sections comprises solid,partially solid, or foamed thermoplastic or thermosetting dielectricmaterials.

In addition an objective is to provide a high performance communicationscable where each of the anvil shaped core-support sections areoptionally singularly filled with individual or paired metal oroptionally coaxial electrical transmitting conductors or optical fiberlight transmitting conductors, or filled with a combination of theindividually or paired metal or optical conductors along thelongitudinal length of the support and the cable.

Another objective is a high performance communications cable where thecable comprises one or more axial strength members and the axialstrength members optionally lie parallel to the interior support insidethe communications cable jacket or within the hollow portion of theinterior support along the longitudinal direction of the support and thecable.

An additional objective is a high performance communications cablecomprising an interior support with an external radial and axial surfaceextending along a longitudinal length of the communications cable, wherethe interior support also has a central region and the central regionalso extends along a longitudinal length of the interior support and thecommunications cable. The interior support comprises a hollow four-petaldaisy shaped arrangement with a central core that may or may not behollow with each of the hollow petals separated by 90 degrees along anaxial plane that extends along a complete length of the communicationscable allowing for individual or paired conductors to be placed withinthe hollow petals.

Additionally an objective is an interior support-separator for acommunications cable comprising an interior support with an externalradial and axial surface extending along a longitudinal length of thecommunications cable with the interior support also having a centralregion also extending along a longitudinal length of the interiorsupport and the communications cable. The interior support comprises ahollow four-petal daisy shaped arrangement with a central core that mayor may not be hollow with each of the hollow petals separated by 90degrees along an axial plane that extends along a complete length of thecommunications cable allowing for individual or paired conductors to beplaced within the hollow petals or within hollow sections of otherwisesolid petals.

An additional objective is a high performance communications cablecomprising an interior support with an external radial and axial surfaceextending along a longitudinal length of the communications cable withthe interior support also having a central region also extending along alongitudinal length of the interior support and the communicationscable. The interior support comprises an inner cross-like separatorsection with rifled sections extending outward into four quadrants awayfrom the central region with the quadrants defined by 90 degree rightangles formed by an intersection of the extended cross-like rifledseparator sections encased within an outer insulated layer which isitself shaped in an identical cross-like pattern as the cross-likeseparator section so that dimensions of the outer insulated layer formsa cross-like pattern larger than the rifled inner cross and functions asa skin for the inner cross-like pattern.

An additional objective is a high performance communications cablecomprising an interior support with an external radial and axial surfaceextending along a longitudinal length of the communications cable withthe interior support also having a central region also extending along alongitudinal length of the interior support and the communicationscable. The interior support comprises a cross-like separator sectionwith zig-zag sections extending outward into four quadrants away fromthe central region, the quadrants defined by 90 degree right anglesformed by an intersection of the extended cross-like zig-zag separatorsections.

Additionally an objective is a high performance communications cablecomprising an interior support with an external radial and axial surfaceextending along a longitudinal length of the communications cable withthe interior support also having a central region also extending along alongitudinal length of the interior support and the communicationscable. The interior support comprises a cross-like separator sectionwith zig-zag sections that have sickle-like ends at each of the sectionszig-zag sections and extend outward into four quadrants away from thecentral region, the quadrants defined by 90 degree right angles formedby an intersection of the extended cross-like zig-zag separator sectionswith the sickle-like ends.

Another objective is an interior support-separator for a communicationscable extending along a longitudinal length of a communications cablecomprising, along its cross-section, a maltese-cross shapedconfiguration with two arm members such that the maltese-cross shape isoptionally skewed along one arm member with an axis along the arm memberproviding a length along one axis of the arm member that is longer thanalong any other axis and providing larger blunt tipped ends at both endsof the arm member. Blunt tipped ends at both ends of an arm member witha length shorter are smaller than the other longer arm member and havean optional hollow orifice in a center region of the central portion ofthe interior support-separator.

Additionally an objective is an interior support-separator for acommunications cable where the maltese-cross shaped cross-sectionalconfiguration along the cross-section includes step-like sections alonga perimeter of the support-separator providing small interstitialsectional grooves along an inner circumferential portion of clearancechannels provided by the support-separator and an optional holloworifice in a center region of the central portion of the interiorsupport-separator.

Another objective is an interior support-separator comprising within across-section, two hollow triangular orifices in the central region ofthe interior support-separator, where the hollow triangular orifices areshaped as equilateral triangles, one of the triangular orifice facingupright and the other triangular orifice facing downward such that thata peak of each triangular orifice is facing opposite directions.

Additionally an objective is an interior support-separator comprisingwithin the cross-section, a diamond shaped orifice in the central regionof the interior support-separator.

Another object is an interior support-separator comprising within thecross-section, a center slit orifice in the central region of theinterior support-separator.

Additionally an objective is a method for producing a high performancecommunications cable by introducing an interior support-separatorsection or sections with a longitudinal length and the external radialand axial surfaces having a central region extending along alongitudinal length of the interior support with the one or moreclearance channels into a jacket of the cable. This is accomplished bypassing a plurality of transmission conductors within the clearancechannels of the interior support-separator through a first die thataligns the plurality of transmission conductors with surface features ofthe internal support allowing for intentional twisting of theconductors. Each of the plurality of conductors are forced into a properclearance channel of the interior support-separator where the clearancechannels are optionally closed by single or double flap-tops maintaininga spatial relationship between each of the transmission conductors.Heating a second die allows for closing of the exterior surface of thechannels. Additionally, taping and twisting of the interior supportallows for closing of the exterior surface of the channels and allowsfor jacketing the interior support containing each of the conductorswithin the clearance channels.

Additionally an objective is a method for producing a high performancecommunications cable by introducing an interior support-separatorsection or sections with a longitudinal length and the external radialand axial surfaces having a central region extending along alongitudinal length of the interior support with one or more hollowcentral ring portions optionally jacketed to complete the cable. Anotherstep is passing a plurality of transmission conductors within the hollowcentral ring portions of the interior support-separator through a firstdie that aligns the plurality of transmission conductors with thesurface features of the internal support allowing for intentionaltwisting of the conductors, forcing each of the plurality of conductorsinto the hollow central ring portions of the interior support-separatorwhere the hollow central ring portions maintain a spatial relationshipbetween each of the transmission conductors by optionally shielding andjacketing the interior support containing each of the conductors withinthe hollow central ring portions and optionally pulling each of thetransmission conductors through the hollow central ring portion(s) orthe support-separators either before, during or after initialinstallation.

An additional objective is a high performance communications cablecomprising an interior support-separator with an external radial andaxial surface extending along a longitudinal length of thecommunications cable with the interior support also having a centralregion also extending along a longitudinal length of the interiorsupport and the communications cable. The support is comprised of apolyolefin based material capable of meeting specific flammability andsmoke generation requirements as defined by UL 910, NAPA 262, and EN50266-2-x, class B test specifications.

An additional objective is a high performance communications cablecomprising an interior support-separator with an external radial andaxial surface extending along a longitudinal length of thecommunications cable with the interior support also having a centralregion also extending along a longitudinal length of the interiorsupport and the communications cable. The support is comprised of athermoplastic based material capable of meeting specific flammabilityand smoke generation requirements as defined by UL 910, NAPA 262, and EN50266-2-x, class B test specifications.

SUMMARY OF THE INVENTION

This invention provides a lower cost communications cable, conductorseparator, and in some cases a conduit tube exhibiting improvedelectrical, flammability, and optionally, optical properties. The cablehas an interior support and in some cases a conduit tube extending alongthe longitudinal length of the communications cable. The interiorsupport has a central region extending along the longitudinal length ofthe interior support. In the preferred configuration, the cable includesa geometrically symmetrical core support-separator with a plurality ofeither solid or foamed multi-shaped, rifled and ladder sections thatextend radially outward from the central region along the longitudinalor axial length of the cable's central region. The coresupport-separator is optionally foamed and has an optional hollowcenter. These various shaped sections of the core support-separator maybe helixed as the core extends along the length of the communicationscable. Each of the adjacent shaped sections defines a clearance whichextends along the longitudinal length of the multi-shaped coresupport-separators. The clearance provides a channel for each of theconductors/optical fibers or conductor pairs used within the cable aswell as for the optional conduit tubes that may be initially empty sothat conductors can be later placed there within. The clearance channelsformed by the various shaped core support-separators extend along thesame length of the central portion. The channels are eithersemi-circular, fully circular, or stepped in a circular-like mannershaped cross-section with completely closed surfaces in the radialdirection toward the center portion of the core and optionally opened orclosed surfaces at the outer radial portion of the same core. Adjacentchannels are separated from each other to provide a chamber for at leasta pair of conductors or an optical fiber or optical fibers. Conduitchannels of various shapes may be used in addition to or in lieu of theadjacent channels.

The various shaped core support-separators of this invention provides asuperior crush resistance to the protrusions of the standard “X” orother similar supports. A superior crush resistance is obtained by thearch-like design for the anvil-shaped separators that provide clearancechannels for additional support to the outer section of the cable. Thevarious shaped cores better preserves the geometry of the pairs relativeto each other and of the pairs relative to the other parts of thecables, such as the possible use of a shield or optical fibers. Theanvil-shape provides an exterior surface that essentially establishesthe desired roundness for cable manufacturers. The exterior roundnessensures ease of die development and eventual extrusion. The roundedsurface of the core also allows for easy accommodation of an overallexternal shield.

The rifled shape separators with ladder-like sections provide similarcrush resistance to the standard “X” supports with the additionalfeature that the center portion of the separator may have solid sectionsthat can be adjusted in step-like increments such that conductor spacingcan be controlled with a degree of precision. Specifically, theconductors can be set apart so that individual or sets of pairs can bespaced closer or farther from one another, allowing for better power sumvalues of equal level far end and near end crosstalk. This “offsetting”between conductor pairs in a logical, methodological pattern to optimizeelectrical properties is an additional benefit associated with therifled shaped separators with ladder-like sections.

According to one embodiment, the cable includes a plurality oftransmission media with metal and/or optical conductors that areindividually disposed; and an optional outer jacket maintaining theplurality of data transmission media in proper position with respect tothe core. The core is comprised of a support-separator having amulti-anvil shaped profile that defines a clearance to maintain aspacing between transmission media or transmission media pairs in thefinished cable. The core may be formed or a conductive or insulativematerial to further reduce cross-talk, impedance, and attenuation. Itmay be solid, foamed, foamed with a solid skin, and composed of a blendof non-halogenated as well as halogenated polymers that also includeinorganic fillers as described above.

Accordingly, the present invention provides for a communications cable,conductor separator and in some cases a conduit tube, with amulti-shaped support-separator, that meets the exacting specificationsof high performance data cables and/or fiber optics or the possibilityof including both transmission media in one cable, has a superiorresistance to deformation during manufacturing and use, allows forcontrol of near-end cross-talk, controls electrical instability due toshielding, is capable of 200 and 1 Ghz (categories 6 and 7 and beyond)transmission with a positive attenuation to cross-talk ratio (ACR ratio)of typically 3 to 10 dB.

Moreover, U.S. Pat. No. 6,639,152 provides a separator so that jacketmaterial (which normally has inferior electrical properties as comparedwith the conductor material) is actually pushed away from the electricalconductor, thus acting to again improve electrical performance (ACR,etc.) over the life of the use of the cable. The anvil-shaped separator,by simple geometric considerations is also superior to the “X” typeseparator in that it increases the physical distance between theconductor pairs within the same cable configuration, as shown in FIGS. 2and 3.

Additionally, it has been known that the conductor pair may actuallyhave physical or chemical bonds that allow for the pair to remainintimately bound along the length of the cavity in which they lie. U.S.Pat. No. 6,639,152 describes a means by which the conductor pairs areadhered to or forced along the cavity walls by the use of grooves. Thisagain increases the distance, thereby increasing the volume of air orother dielectrically superior medium between conductors in separatecavities. As discussed above, spacing between pairs, spacing away fromjackets, and balanced spacing all have an effect on final electricalcable performance.

It is an object of the present invention to provide a data/multi-mediacable that has a specially designed interior support that accommodatesconductors with a variety of AWG's, impedances, improved crushresistance, controlled NEXT, controlled electrical instability due toshielding, increased breaking strength, and allows the conductors, suchas twisted pairs, to be spaced in a manner to achieve positive ACRratios using non-conventional composite compound blends that includehalogenated and non-halogenated polymers together with optionalinorganic and organic additives that include inorganic salts, metallicoxides, silica and silicon oxides as well as any number of substituteand unsubstantiated fullerenes.

It is still another object of the invention to provide a cable that doesnot require individual shielding and that allows for the precise spacingof conductors such as twisted pairs and/or fiber optics with relativeease. In the present invention, the cable would include individual glassfibers as well as conventional metal conductors as the transmissionmedium that would be either together or separated in clearance channelchambers provided by the anvil-shaped sections of the coresupport-separator or could be placed either immediately or at a latertime into conduit tubes.

Another embodiment of the invention includes having a multi-shaped coresupport-separator with a central region that is either solid orpartially solid. Again this support-separator and any conduit tube wouldbe comprised of the special composite compound blends described indetail above. This again includes the use of a foamed core and/or theuse of a hollow center of the core, which in both cases significantlyreduces the material required along the length of the finished cable.The effect of foaming and/or producing a support-separator with a hollowcenter portion should result in improved flammability of the overallcable by reducing the amount of material available as fuel for the UL910 test, improved electrical properties for the individual non-opticalconductors, and reduction of weight of the overall cable.

A further embodiment includes the fully opened surface sections definingthe core clearance channels which extend along the longitudinal lengthof the multi-anvil shaped core support-separator as provided in U.S.Pat. No. 6,639,152. This clearance provides half-circular channel wallsfor each of the conductors/optical fibers or conductor pairs used withinthe cable. A second version of this embodiment includes a semi-closed orsemi-opened surface section defining the same core clearance channelwalls. These channel walls would be semi-circular to the point that atleast 200 degrees of the potential 360 degree wall enclosure exists.Typically, these channels walls would include and opening of 0.005inches to 0.011 inches wide. A third version of this embodiment includeseither a fully closed channel or an almost fully closed channel of theanvil-shaped core support-separator such that this version could includethe use of a “flap-top” initially providing an opening for insertion ofconductors or fibers and thereafter providing a covering for these sameconductors or fibers in the same channel. The flap-top closure can beaccomplished by a number of manufacturing methods including heat sealingduring extrusion of the finished cable product. Other methods include apress-fit design, taping of the full assembly, or even a thin skinextrusion that would cover a portion of the multi-anvil shapedseparator. All such designs could be substituted either in-lieu of aseparate cable jacket or with a cable jacket, depending on the finalproperty requirements. All such designs of the present invention wouldincorporate the use if the special composite compound blends aspreviously described.

Yet another embodiment provided in U.S. Pat. No. 6,639,152 that isincluded in the present invention allows for interior corrugatedclearance channels provided by the multi-shaped sections of the coresupport-separator. This corrugated internal section has internal axialgrooves that allow for separation of conductor pairs from each other oreven separation of single conductors from each other as well asseparation of optical conductors from conventional metal conductors.Alternatively, the edges of said grooves may allow for separation thusproviding a method for uniformly locating or spacing the conductor pairswith respect to the channel walls instead of allowing for randomfloating of the conductor pairs.

Each groove can accommodate at least one twisted pair. In someinstances, it may be beneficial to keep the two conductors in intimatecontact with each other by providing grooves that ensure that the pairsare forced to contact a portion of the wall of the clearance channels.The interior support provides needed structural stability duringmanufacture and use. The grooves also improve NEXT control by allowingfor the easy spacing of the twisted pairs. The easy spacing lessens theneed for complex and hard to control lay procedures and individualshielding. Other significant advantageous results such as: improvedimpedance determination because of the ability to precisely placetwisted pairs: the ability to meet a positive ACR value from twistedpair to twisted pair with a cable that is no larger than an ISTP cable;and an interior support which allows for a variety of twisted pair andoptical fiber dimensions.

Still another related embodiment includes the use of an exteriorcorrugated or convoluted design such that the outer surface of thesupport-separator has external radial grooves along the longitudinallength of the cable. This exterior surface can itself function as ajacket if the fully closed anvil-shaped version of the invention asdescribed above is utilized. Additionally, the jacket may have acorrugated, smooth or ribbed surface depending on the nature of theinstallation requirements. In raceways or plenum areas that are new andno previous wire or cable has been installed, the use of corrugatedsurfaces can enhance flex and bending mechanical strength. For otherinstallations, a smooth surface reduces the possibility of high frictionwhen pulling cable into areas where it may contact surfaces other thanthe raceway or plenum. Mechanical integrity using an outer jacket suchas depicted in FIG. 2 a, 2 b, or 2 c may be essential for installationpurposes.

Alternatively, depending on manufacturing capabilities, the use of atape or polymeric binding sheet may be necessary in lieu of extrudedthermoplastic jacketing. Taping or other means may provide specialproperties of the cable construction such as reduced halogen content orcost and such a construction is found in FIG. 2 c.

Yet another related embodiment includes the use of a strength membertogether with, but outside of the multi-anvil shaped coresupport-separator running parallel in the longitudinal direction alongthe length of the communications cable. In a related embodiment, thestrength member could be the core support-separator itself, or in anadditional related embodiment, the strength member could be inserted inthe hollow center-portion of the core.

According to another embodiment of the invention, the multi-anvil shapedcore support-separator optionally includes a slotted section allowingfor insertion of an earthing wire to ensure proper and sufficientelectrical grounding preventing electrical draft.

It is possible to leave the multi-anvil shaped separator cavities emptyin that the separator itself or within a jacket would be pulled intoplace and left for future “blown fiber” or other conductors along thelength using compressed air or similar techniques such as use of apulling tape or the like

Additional embodiments to the invention include the use of rifled shapeseparators with ladder-like sections to provide similar crush resistanceto the standard “X” supports. These rifled sections, however, have theadditional feature that the center portion of the separator may includesolid sections that can be adjusted in step-like increments such thatconductor spacing can be controlled with a degree of precision.Specifically, the conductors can be set apart so that individual pairsor sets of pairs can be spaced closer or farther from one another,allowing for better power sum values of equal level far end and near endcross-talk. This “offsetting” between conductor pairs in a logical,methodological pattern to optimize electrical properties, is anadditional benefit associated with the rifled shaped separators withladder-like sections.

It is to be understood that each of the embodiments above could includea flame-retarded, smoke suppressant version and that each could includethe use of recycled or reground thermoplastics in an amount up to 100%.

A method of producing the communications cable, introducing any of themulti-shaped core separators as described above, into the cableassembly, is described as first passing a plurality of transmissionmedia and a core through a first die which aligns the plurality oftransmission media with surface features of the core and prevents orintentionally allows twisting motion of the core. Next, the methodbunches the aligned plurality of transmission media and core using asecond die which forces each of the plurality of the transmission mediainto contact with the surface features of the core which maintain aspatial relationship between each of plurality of transmission media.Finally, the bunched plurality of transmission media and core areoptionally twisted to close the cable, and the closed cable optionallyjacketed.

Other desired embodiments, results, and novel features of the presentinvention will become more apparent from the following drawings anddetailed description and the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a top-right view of one embodiment of the cable andseparator that includes solid or foamed polymeric smooth internal andexternal surfaces.

FIG. 1 b is a top-right view of one embodiment of the cable andseparator that includes solid or foamed polymeric grooved internal andexternal surfaces.

FIG. 1 c is a top-right view of one embodiment of the cable andseparator that includes solid or foamed polymeric corrugated internaland external surfaces.

FIG. 2 a is a top-right view of one embodiment of the cable andseparator that includes an anvil-shaped separator and a smooth/ribbedjacket.

FIG. 2 b is a top-right view of another embodiment of the cable andseparator that includes a ribbed, corrugated jacket.

FIG. 2 c is a top-right view of another embodiment of the cable andseparator that includes a taped or polymer binder sheet jacketingconfiguration.

FIG. 3 a is a cross-section end view of the interior support oranvil-shaped separator taken along the horizontal plane of the interiorsupport anvil-shaped separator.

FIG. 3 b is a cross-section end view of the single flap, flap-topembodiment of the interior support or anvil-shaped separator taken alongthe horizontal plane of the interior support anvil-shaped separator whenthe flap is open.

FIG. 3 c is a cross-section end view of the single flap, flap-topembodiment of the interior support or anvil-shaped separator taken alongthe horizontal plane of the interior support anvil-shaped separator whenthe flap is closed.

FIG. 3 d is an enlarged detailed version of the closed single-flap,flap-top embodiment of the anvil-shaped separator.

FIG. 3 e is a cross-section end view of the single flap, flap-topembodiment of the interior support or anvil-shaped separator taken alongthe horizontal plane of the interior support anvil-shaped separator whenthe flap is closed.

FIG. 3 f is an enlarged detailed version of the closed single-flap,flap-top embodiment of the anvil-shaped separator.

FIG. 4 a is a cross-section end view of the double flap, flap-topembodiment of the interior support or anvil-shaped separator taken alongthe horizontal plane of the interior support or anvil-shaped separatorwhen the flaps are open.

FIG. 4 b is a cross-section end view of the double flap, flap-topembodiment of the interior support or anvil-shaped separator taken alongthe horizontal plane of the interior support or anvil-shaped separatorwhen the flaps are closed.

FIG. 4 c is an enlarged detailed version of the closed double-flap,flap-top embodiment of the anvil-shaped separator.

FIG. 5 is a cross-section end view of a flap-top embodiment of theinterior support anvil-shaped separator taken along the horizontal planeof the interior support anvil-shaped separator where the separator maycontain one or more optical fibers in each of four channels.

FIG. 6 is a cross-section end view of a cable containing an anvil shapedseparator and four smaller anvil-shaped separators taken along thehorizontal plane of the cable.

FIG. 7 a is a cross-section end view of a cable containing sixanvil-shaped separators taken along the horizontal plane of the cablewith six rifled cross, symmetrically-even shaped separators (as shown inFIG. 18) with a hollow core feature.

FIG. 7 b is a cross-section end view of a cable containing sixanvil-shaped separators taken along the horizontal plane of the cablewith six anvil-shaped separators with a center core with conductivewires.

FIG. 8 a is a cross-section end view of an anvil-shaped separator whereboth outer sharp edged ends of the anvil have been replaced with roundedregions to reduce weight and provide a larger opening for each channeldefined by the anvil-shaped separator.

FIG. 8 b is also a cross-section end view of an anvil-shaped separatorwhere both outer sharp edged ends of each anvil section are replacedwith rounded regions and each anvil section includes a channel for adrain wire.

FIG. 9 is a cross-section end view of an anvil-shaped separator wheredual lobed anvil sections are minimized in size to provide the greatestpossible channel girth and opening while still maintaining an anvil-likeshape and each dual lobed section includes a channel for a drain wire.

FIG. 10 is a cross-section end view of a relatively large cable forconductor separation with six (6) anvil shaped sections and an adjacentsection for a fifth conductor pair.

FIG. 11 is a cross-section end view of a skewed maltese-cross typeseparator for “worst” pair spacing.

FIG. 12 a is a cross-section end view of a rifled and (optionally)skewed maltese-cross type separator.

FIG. 12 b is an enlarged detailed version of the cross-section end viewof a rifled and (optionally) skewed maltese-cross type separator.

FIG. 13 a is a cross-section end view of a diamond shaped separator.

FIG. 13 b is a cross-section end view of a diamond shaped separator witha center circular orifice.

FIG. 13 c is a cross-section end view of a diamond shaped separator withequilateral triangular slots.

FIG. 13 d is a cross-section end view of a diamond shaped separator witha diamond shaped center orifice or slot.

FIG. 14 is a cross-section end view of a pendulum-like shaped separatorwith a circular disc pendant near its center

FIG. 15 is a cross-section end view of a pendulum-like shaped separatorwith an elliptical-disc pendant near its center

FIG. 16 is a cross-section end view of a pendulum-like shaped separatorwith a diamond-disc shaped pendant near its center

FIG. 17 is a cross-section end view pendulum-like dual lobed shapedseparator with a diamond-disc shaped pendant near its center

FIG. 18 is a cross-section end view of a rifled cross,symmetrically-even shaped separator.

FIG. 19 is a cross-section end view of a mirrored battleship-shaped andinverted separator with top-side and bottom-side key-way shapedsections.

FIG. 20 is a cross-section end view of a staggered and rifledsymmetrical cross shaped separator.

FIG. 21 a is a cross-sectional view of an asymmetric cross-shapedseparator.

FIG. 21 b is a cross-sectional view of an asymmetric cross-shapedseparator with rifled or “saw-blade” like members.

FIG. 22 is a cross-sectional view of a saw-blade horizontal member-typeseparator.

FIG. 23 a is a cross-sectional view of a symmetrical “Z” or angle-ironshaped type separator.

FIG. 23 b is a cross-sectional view of a symmetrical “Z” or angle-ironshaped type separator with rifled or “saw-blade” like members.

FIG. 24 a is a cross-section view of one embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending rifled protrusions eachextending in a preferred 90 degree separation from each other foroptimum pair separation. The central ring portion optionally includes ahollow region to act as an air blown fiber (ABF) duct which is availablefor filling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 24 b is a cross-section view of a second embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a, but also includes a second innerring within the hollow region comprised of a different material than theouter ring for either increasing lubricity or friction with fourextending rifled protrusions each extending in a preferred 90 degreeseparation from each other for optimum pair separation.

FIG. 24 c is a cross-section view of a third embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a, but also includes a second innerring within the hollow region comprised of a different material than theouter ring for either increasing friction utilizing rifled interspatially arranged sections with four extending rifled protrusions eachextending in a preferred 90 degree separation from each other foroptimum pair separation.

FIG. 24 d is a cross-section view of a third embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 c, but also includes the optionaluse of a organic or inorganic fibers including a polyamide (for exampleKevlar®) filing and an optional strength member within the second innerring within the hollow region comprised of a different material than theouter ring as well as allowing for multiple separate multimode or singlemode fiber optic units also contained within the same hollow region withfour extending rifled protrusions each extending in a preferred 90degree separation from each other for optimum pair separation.

FIG. 24 e is a cross-section view of a fifth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 b and also includes an inner pulltape for attaching optical fibers or metallic conductors wherein thetape optionally itself incorporates a grip or for which a grip isprovided for future pulling of those communication media through thehollow region at some future time or during an installation with fourextending rifled protrusions each extending in a preferred 90 degreeseparation from each other for optimum pair separation.

FIG. 24 f is a cross-section view of a sixth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 b but also two individual conductors(which may be twisted) inside the second inner ring which is smoothinstead of rifled within the hollow region and comprised of a differentmaterial than the outer ring as well as allowing for multiple separatemultimode or single mode fiber optic units also contained within thesame hollow region with four extending rifled protrusions each extendingin a preferred 90 degree separation from each other for optimum pairseparation.

FIG. 24 g is a cross-section view of a seventh embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a with four extending rifledprotrusions each extending in a preferred 90 degree separation from eachother for optimum pair separation, but also includes the optionaladdition of one or more coaxial conductors contained in the centerhollow region.

FIG. 25 a is a cross-section view of an another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a but possesses 6 instead of 4rifled protrusions each extending in a preferred degree separation fromeach other for optimum pair separation.

FIG. 25 b is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 25 a but with an inner rifled ringsection with as few as two and as many as six extending protrusions eachextending in a preferred degree separation along the outer ring fromeach other for optimum pair separation.

FIG. 25 c is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 25 a but with an inner smooth ringsection with as few as two and as many as six extending protrusions eachextending in a preferred degree separation along the outer ring fromeach other for optimum pair separation that optionally includes theaddition of one or more conductors including optionally organic orinorganic fibers such as polyamide (for example Kevlar®) filling and anoptional strength member within the second inner ring.

FIG. 25 d is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 25 c with an inner smooth ring sectionwith as few as two and or as many as six extending protrusions eachextending in a preferred degree separation along the outer ring fromeach other for optimum pair separation that optionally includes theaddition of one or more conductors including optionally organic orinorganic fibers such as polyamide (for example Kevlar®) filing and anoptional strength member within the second inner ring. Also, between asfew as one and as many as six of the extending projections, additionaldaisy-like spacers (as shown in FIG. 28 a) are placed which themselvesallow for spacing of individual conductors or conductor pairs.

FIG. 25 e is a cross-section view of another embodiment of the cablesupport separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 25 c with an inner smooth ring sectionwith as few as two and as many as six extending protrusions eachextending in a preferred degree separation along the outer ring fromeach other for optimum pair separation that optionally includes theaddition of one or more conductors including optionally organic orinorganic fibers such as polyamide (for example Kevlar®) filling and anoptional strength member within the second inner ring. Also, between asfew as one and as many as six of the extending projections are shownwithout the additional daisy-like spacers (as shown in FIG. 28 a).

FIG. 25 f is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 25 c with an inner smooth ring sectionwith as few as two and as many as six extending protrusions eachextending in a preferred degree separation along the outer ring fromeach other for optimum pair separation that optionally includes theaddition of one or more conductors including optionally organic orinorganic fibers such as polyamide (for example Kevlar®) filling and anoptional strength member within the second inner ring. Also, between asfew as one and as many as six of the extending projections, additionalspacers comprised of a region which includes rounded lobes in asymmetric diamond-like geometry that defines as many as four separateregions for pairs that are properly separated in the final (oftenjacketed) cable design (as shown in FIG. 29 a) are placed whichthemselves allow for spacing of individual conductors of conductorpairs.

FIG. 26 a is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smoother protrusions, eachprotrusion extending less than those of FIGS. 24 a through 25 f, eachagain extending in a preferred 90 degree separation from each other foroptimum pair separation. The central ring portion optionally includes ahollow region to act as an air blown fiber (ABF) duct which is availablefor filling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 26 b is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 24 a through 25 f, eachagain extending in a preferred 90 degree separation from each other foroptimum pair separation and also includes a second inner ring within thehollow region comprised of a different material than the outer ring foreither increased lubricity or friction. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smootherinternal and external surfaces.

FIG. 26 c is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions eachprotrusion extending less than those of FIGS. 24 a through 25 f, eachagain extending in a preferred 90 degree separation from each other foroptimum pair separation and also includes a second inner ring within thehollow region comprised of a different material than the outer ring forincreasing friction utilizing rifled inner spatially arranged sections.The central ring portion optionally includes a hollow region to act asan air blown fiber (ABF) duct which is available for filling withoptical fiber which is comprised of solid, semi-solid, foamed or hollowpolymeric smooth internal and external surfaces.

FIGS. 26 d and 26 e are cross-section views of another embodiment of thecable support-separator that includes a symmetrical core with a centralcircular ring region with as few as two and as many as six extendingsmoother protrusions, each protrusion extending less than those of theseries of FIGS. 24 a through 25 f, each again extending in a preferredseparation from each other for optimum pair separation and also includesalso includes a an optional second inner ring within the hollow regioncomprised of a different material than the outer ring for increasingfriction utilizing rifled inner spatially arranged sections. The centralring portion optionally includes a hollow region to act as an air blowfiber (ABF) duct which is available for filling with optical fiber whichis comprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 26 f is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with no extending protrusions that includes also anoptional second inner ring within the hollow region comprised of adifferent material than the outer ring for increasing friction utilizingrifled inner spatially arranged sections. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 27 a is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending protrusions each protrusionextending less than those of FIGS. 24 a through 25 f and each with atleast a single cross-like section extending outward from the circularring section in a preferred 90 degree separation from each other foroptimum pair separation. The central ring portion optionally includes ahollow region to act as an air blown fiber (ABF) duct which is availablefor filling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 27 b is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of FIGS. 24 a through 25 f, each again extending in apreferred 90 degree separation from each other for optimum pairseparation and also includes a second inner ring within the hollowregion comprised of a different material than the outer ring for eitherincreasing lubricity or friction. The central ring portion optionallyincludes a hollow region to act as an air blown fiber (ABF) duct whichis available for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 27 c is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of FIGS. 24 a through 25 f, each again extending in apreferred 90 degree separation from each other for optimum pairseparation and also includes a second inner ring within the hollowregion comprised of a different material than the outer ring for eitherincreasing lubricity or friction. The inner portion of the hollow ringregion here is optionally filled with inorganic or organic fibers suchas polyamide fiber (Kevlar®) and at least four single or multimode fiberoptic units.

FIGS. 27 d and 27 e include a cross-section view of another embodimentof the cable support-separator that includes a symmetrical core with acentral circular ring region with as few as two and as many as sixextending protrusions each with at least a single cross-like section,each protrusion extending less than those in of FIGS. 24 e through 25 f,each again extending in a preferred separation from each other foroptimum pair separation and also includes also includes an optionalsecond inner ring within the hollow region comprised of a differentmaterial than the outer ring for increasing friction utilizing rifledinner spatially arranged sections. The central ring portion optionallyincludes a hollow region to act as an air blown fiber (ABF) duct whichis available for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 27 f includes a cross-section view of another embodiment of thecable support-separator includes a symmetrical core with a centralcircular ring region with no extending protrusions that includes also anoptional second inner ring within the hollow region comprised of adifferent material than the outer ring for increasing friction utilizingrifled inner spatially arranged sections. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 28 a is a cross-section view of another embodiment of the cablesupport-separator that includes a hollow four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. If thecentral region is hollow, the possibility again exists for that regionto act as an air blown fiber (ABF) duct which is available for fillingwith optical fiber. Coaxial or twisted pair conductors may also beintroduced in that region.

FIG. 28 b is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. Each“petal” contains two hollow sections for additional optical or metallicconductor media. The central region is hollow allowing for thepossibility that this region may act as an air blown fiber (ABF) ductwhich is available for filling with optical fiber. Coaxial or twistedpair conductors may also be introduced in that region.

FIG. 28 c is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. Each“petal” contains three hollow sections of differing diameters foradditional optical or metallic conductor media. The central region issolid.

FIG. 28 d is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. Each“petal” contains three hollow sections of differing diameters foradditional optical or metallic conductor media. In this case, the centerhollow section of each petal is filled with an optical fiber unit. Thecentral region is solid or optionally hollow.

FIG. 28 e is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. In thiscase, the center hollow section is filled with an optical fiber unit.

FIGS. 29 a, 29 b, 29 c are cross-sectional views of another set ofembodiments of the cable support-separator that includes a circular ringregion which is surrounded by rounded lobes in a symmetric diamond-likegeometry that defines as many as four separate regions for pairs thatare properly separated in the final (often jacketed) cable design.Against the central ring portion can optionally include a hollow regionthat may be used as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smoother internal and external surfaces. FIG.29 a has no inner ring. FIG. 29 b has a smooth inner ring withoptionally different material than the outer ring, and FIG. 29 c has aan inner ring with rifled sections. Each can optionally be used for coaxor twisted pair as well as for fiber optic conductors in advance, duringor after installation.

FIG. 29 d is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes the optional addition of one or more conductors includingoptionally organic or inorganic fibers such as a polyamide (for exampleKevlar®) filling and an optional strength member within the second innerring (that may or may not be rifled). Again the central ring portion canoptionally include a hollow region that may be used as an air blownfiber (ABF) duct which is available for filling with optical fiber whichis comprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 29 e is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion filled with a fiber optic unit as well as fourseparated conductor pairs in each of the regions defined by thesymmetric diamond-like geometry of the cable support-separator. Againthe central ring portion can optionally include a hollow region that maybe used as an air blown fiber (ABF) duct which is available for fillingwith optical fiber which is comprised of solid, semi-solid, foamed orhollow polymeric smooth internal and external surfaces.

FIG. 29 f is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion with a second inner ring portion filled with afiber optic unit or other conductors as well as four cross-likeseparators (see FIG. 30 a) in each of the regions defined by thesymmetric diamond-like geometry of the cable support-separator withinwhich another, up to four pairs of conductors are situated and separatedby the cross-like separator. Again the central ring portion canoptionally include a hollow region that may be used as an air blownfiber (ABF) duct which is available for filling with optical fiber whichis comprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 30 a is a cross-section view of another embodiment of the cablesupport-separator that includes a more conventional cross-like separatorsection with “rifled” sections extending outward into four quadrantsaway from the central region and is encased or covered within an outerinsulated layer which is itself shaped in an identical cross except thatthe dimensions of this outer cross is larger than the rifled inner crossand functions as a “skin”. The inner cross-like portion may bemetallized by utilizing electroless or electrolytic plating techniquesover a thermoplastic.

FIG. 30 b is a cross-section view of another embodiment of the cablesupport-separator that includes the same more conventional cross-likeseparator section as with FIG. 30 a except that this separator containsa shield that extends along the horizontal axis and optionally alsoalong the vertical axis or both axes within the horizontal hollowportion of the cross-like separator. This shield is comprised ofaluminum PET film and may be configured so that it is held within theouter cross-like separator. The design also allows for shieldingexterior to the separator under a jacketed cable containing theseparator.

FIG. 31 a is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “zig-zag” extensions that extend away from thecentral region. Again the cross-like “zig-zag” arrangement may becovered within an outer insulated layer which is itself shaped in anidentical cross except that the dimensions of this outer cross arelarger than the rifled inner cross and functions as a “skin”.

FIG. 31 b is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “sickle-like” extensions that extend away from thecentral region. Again the cross-like and sickle-like arrangement may becovered within an outer insulated layer which is itself shaped in anidentical cross except that the dimensions of this outer cross arelarger than the rifled inner cross and functions as a “skin”.

FIG. 32 is a cross-sectional view of another embodiment with severalhollow regions for blown fiber or any transmission media for present,future, or concurrent installations using the support-separator alone orin combination with a cable.

FIGS. 33 a and 33 b are cross-sectional views of another set ofembodiments of the cable support-separator that includes a circular ringregion which is surrounded by semi-rounded lobes in a symmetricstar-like geometry that defines as many as four separate regions forpairs that are properly separated in the final (often jacketed) cabledesign. Again the central ring portion can optionally include a hollowregion that may be used as an air blown fiber (ABF) duct which isavailable for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces. FIGS. 33 a and 33 b include view of optionally filled innerhollow regions such that each can optionally be used for coax or twistedpair as well as for fiber optic conductors (in advance, during or afterinstallation).

DETAILED DESCRIPTION OF THE DRAWINGS

The following description will further help to explain the inventivefeatures of the cable and the interior support portion of the cable.

FIG. 1 a is a top-right view of one embodiment of this invention. Theshown embodiment has an interior support shown as an anvil-shapedseparator (110). The interior support anvil-shaped separator, shown inmore detail in FIGS. 3 and 4, runs along the longitudinal length on thecable. The interior support anvil-shaped separator, hereinafter, in thedetailed description, referred to as the “anvil-shaped separator”, has acentral region (112) extending along the longitudinal length of thecable. The center region includes a cavity that runs the length of theseparator in which a strength member (114) may be inserted.

Channels 120, 122, 124, and 126 extend along the length of theanvil-shaped separator and provide compartments for conductors (130).

A strength member may be added to the cable. The strength member (114)in the shown embodiment is located in the central region of theanvil-shaped separator. The strength member runs the longitudinal lengthof the anvil-shaped separator. The strength member is a solidpolyethylene or other suitable plastic, textile (nylon, aramid, etc.),fiberglass flexible or rigid (FGE rod), or metallic material.

Conductors, such as the shown insulated twisted pairs, (130) aredisposed in each channel. The pairs run the longitudinal length of theanvil-shaped separator. While this embodiment depicts one twisted pairper channel, there may be more than one pair per channel. The twistedpairs are insulated with a suitable polymer, copolymer, or dual extrudedfoamed insulation with solid skin surface. The conductors are thosenormally used for optical or conventional data transmission. The twistedpairs may be bonded such that the insulation of each conductor isphysically or chemically bound in an adhesive fashion, or an externalfilm could be wrapped around each conductor pair to provide the sameeffect. Although the embodiment utilizes twisted pairs, one couldutilize various types of insulated conductors within the anvil-shapedseparator channels or cavities.

A metal drain wire may be inserted into a specially designated slot(140). The drain wire functions as a ground or earthing wire. It alsoserves to reduce material content and maybe applicable to eachanvil-type separator.

FIG. 1 b is another embodiment that includes grooves (150) on either theexterior surface of the separator or within the channels of theseparator or both. The interior grooves within the channels of thisembodiment are specifically designed so that at least a single conductorof a conductor pair can be forced along the inner wall of the groove,thereby allowing for specific spacing that improves electricalproperties associated with the conductor or conductor pair. A crosssection of this separator with channeled grooves is shown and discussedin a later figure.

FIG. 1 c is yet another related embodiment that includes the use of anexterior corrugated design (160) such that the outer surface of thesupport-separator has external radial grooves along the longitudinallength of the cable. This exterior surface can itself function as ajacket if the fully closed anvil-shaped version of the invention asdescribed above is utilized. Optionally, this corrugated version of FIG.1 c may also include the channeled grooves shown in FIG. 1 b.

The anvil-shaped separator may be cabled with a helixed configuration.The helically twisted portions (165) in turn define helically twistedconductor receiving grooves within the channels that accommodate thetwisted pairs or individual optical fibers.

The cable (200), as shown in FIG. 2 a is a high performance cablecapable of greater than 600 MHz and easily reaching 2 Ghz or greater.The cable has an optional outer jacket (210) that can be athermoplastic, polyvinyl chloride, a fluoropolymer or a polyolefin, or athermoset, with or without halogen free material as required byflammability, smoke generation, corrosivity, or toxicity, and electricalspecifications as detailed above. Additionally, the jacket may be eithercorrugated (220) as in FIG. 2 b or smooth/ribbed (210) depending on thenature of the installation requirements. Mechanical integrity using anouter jacket such as depicted in FIGS. 2 a and 2 b, may be essential forinstallation purposes.

FIG. 2 b is another embodiment that includes grooves along the interiorchannels of the separator. The interior grooves (225) within thechannels of this embodiment are also specifically designed so that atleast a single conductor of a conductor pair can be forced along theinner wall of the groove, thereby allowing for specific spacing thatimproves electrical properties associated with the conductor orconductor pair.

Over the anvil shaped separator optional polymer binder sheet or tape orsheets or tapes (230) that may be non-wovens such as polyimide,polyether-imide, mica, or other fire retardant inorganic tapes may beused as shown in FIG. 2 c for circuit integrity cable. The binder iswrapped around the anvil shaped separator (200) to enclose the twistedpairs or optical fiber bundles. The binder or tape itself maybe alaminated aluminum shield or the aluminum shield may also be includedunder the polymer binder sheet. The electromagnetic interference andradio frequency (EMI-RFI) shield is a tape with a foil or metal surfacefacing towards the interior of the jacket that protects the signalscarried by the twisted pairs or fiber cables from electromagnetic orradio frequency distortion. The shield may be composed of a foil and hasa belt-like shield that can be forced into a round, smooth shape duringmanufacture. This taped embodiment with shield may be utilized tocontrol electrical properties with extreme precision. This shieldedversion is capable of at least 1 Ghz or higher frequency signalpropagation. Each of the individual conductor pairs may themselves beindividually shielded. A metal drain wire may be inserted into aspecially designated slot (240) that then can be subsequently wrappedaround the shield. The drain wire within the slot runs the length of thecable. The drain wire functions as a ground or earthing wire.

Use of the term “cable covering” refers to a means to insulate andprotect the cable. The cable covering being exterior to said anvilmember and insulated conductors disposed in grooves provided within theclearance channels. These grooves within clearance channels allow forproper insertion of conductors. Recent developments in communicationscabling has shown that improvements in electrical properties can beaccomplished if “worst” pair conductors are spaced such that they arephysically further removed from other “worst pair” conductors. “Worstpair” refers to two conductors that are physically matched and can behelically twisted around each other such that electrical properties suchas attenuation, crosstalk, and impedance properties are least favorablein comparison with other similarly paired conductors. Inevitably, duringcable manufacture, at least one set of paired conductors exhibit these“worst pair” parameters and a major attribute of this invention is tospace these “worst pairs” far from the better electrical transmissionperforming pairs. Parallel pair conductors with individual shielding canalso be used to achieve the present invention.

The outer jacket, shield, drain spiral and binder described in the shownembodiment provide an example of an acceptable cable covering. The cablecovering, however, may simply include an outer jacket or may includejust the exterior surface (corrugated or convoluted with ribbed orsmooth surfaces) of the anvil shaped interior support member.

The cable covering may also include a gel filler to fill the void space(250) between the interior support, twisted pairs and a portion of thecable covering,

The clearance channels formed by the anvil shaped interior supportmember of the present inventive cable design allows for precise supportand placement of the twisted pairs, individual conductors, and opticalfibers. The anvil shaped separator will accommodate twisted pairs ofvarying AWG's and therefore of varying electrical impedance. The uniquecircular shape of the separator provides a geometry that does not easilycrush and allows for maintenance of a cable appearing round in finalconstruction.

The crush resistance of the inventive separator helps preserve thespacing of the twisted pairs, and control twisted pair geometry relativeto other cable components. Further, adding a helical twist allows forimproving overall electrical performance design capability whilepreserving the desired geometry.

The optional strength member located in the central region of the anvilshaped separator allows for the displacement of stress loads away fromthe pairs.

FIG. 3 a is a horizontal cross-section of a preferred embodiment of theanvil-shaped separator. The anvil-shaped separator can be typicallyapproximately 0.210 inches in diameter. It includes four channels (300,302, 304, and 306) that are typically approximately 0.0638 to 0.0828inches in diameter. The channel centers are 90 degrees apart relative tothe center of the separator. Each channel is typically approximately0.005 inches from the channel across from it, and each channel isapproximately 0.005–0.011 inches apart form its two nearest-neighboringchannels at their closest proximity. Inserted in the channels is one setof twisted pairs (310, 312, 314, and 316) with the option for addingtwisted pairs to each channel denoted by dashed circles. In a preferredembodiment, each channel has typically a 0.037-inch opening along itsradial edge that allow for the insertion of the twisted pairs. Thisembodiment also includes a cavity in the center of the anvil-shapedseparator for a strength member (320). Additionally, there is a slot fora drain or earthing wire (330). The exploded view of FIG. 3 a alsoindicates the use of an interior slotted rifled section or sections(332) that allows for less bulk material based on overall depth of theslots of the rifled section, improves electrical characteristics asdescribed above regarding worst pair conductors (allowing for more airaround each insulated conductor or pair), and physically binds the pairstogether so that each pair has semi-permanently fixed position. As shownin the other exploded view (334), the individual conductor may compressagainst the solid or foamed slotted rifled surface to ensure thesemi-permanently fixed position.

FIG. 3 b is another embodiment of the anvil-shaped separator. Theanvil-shaped separator includes a single flap-top (340, 342, 344, and346) that is initially in an open position to allow the twisted pairs tobe inserted into the channels. In FIG. 3 c the flap-tops are in theclosed position (350, 352, 354, and 356) where the flap-top (360) fitsinto a recessed portion of the separator (365) for closure. Theflap-tops (360) are self-sealing when heat and/or pressure is applied,such that elements within the channels can no longer be removed from theseparator and such that the channels containing the twisted pairs areenclosed. The flap-top (360) is shown in more detail in FIG. 3 d.

FIG 3 e is another embodiment of the anvil-shaped separator. Theanvil-shaped separator includes a single flap-top (380, 382, 384, and386) that is depicted in the closed position. When in the closedposition, the flap-top (390) overlaps the outer portion (395) of theseparator. The amount of overlap required will depend on several designand manufacturing factors and the shown embodiment is only intended asone example of the overlap required. The flap-tops (390) areself-sealing when heat and/or pressure is applied, such that theelements within the channels can no longer be removed or displaced fromthe separator and such that the channels containing twisted pairs areenclosed. The flap-top (390) is shown in more detail in FIG. 3 f.

Another embodiment of FIGS. 3 a, 3 b and 3 c includes all of theaforementioned features without the drain wire or drain wire slot (330),but may include the center hole (320) for strength members. Use of acenter hole (320) is also important in that it reduces the mass requiredfor the spacing. It has been shown and reported in prior art journalsand publications that the total mass of the organic components of thecable is directly proportional to flame spread and smoke generation. Asmass is reduced, the probability that the cable will pass more stringentflame testing (such as U.L. 910/NFPA 262/IEC 60332-3B₁/IEC 60332-3B₂ aspreviously described) significantly increases.

A further embodiment of FIGS. 3 a, 3 b and 3 c includes all theaforementioned features without the center hole (320) for strengthmembers and without the drain wire or drain wire slot (330).

FIG. 4 a is a horizontal cross-section of a preferred embodiment of theanvil-shaped separator that is identical to FIG. 3 b but has a pair ofoverlapping section instead of the single overlapping section of FIG. 3b and may include optional “stepped” or “rifled” grooves that existalong the inner circumference of the clearance channels. These groovescan be larger in diameter than pictured and used to improve spacing ofthe “worst pair” conductors as described earlier. These rifled clearancechannels can be used to “squeeze” the conductors or conductor pairs intothe interstitial openings creating a more permanent positioning thatwill enhance the electrical characteristics of the final cable assembly.If properly positioned during the “twinning” and subsequent forming ofthe cable, the forced positioning of the conductors in the rifledsections will improve signal performance. The anvil-shaped separatorincludes double flap-tops (440, 442, 444, and 446) that are initially inan open position to allow the twisted pairs to be inserted into thechannels. In FIG. 4 b (exploded view of FIG. 4 c) the flap-tops are inthe closed position (450, 452, 454, and 456). The flap-tops are againstself-sealing in the presence of heat and/or pressure and the channelscontaining the twisted pairs are subsequently enclosed. The flap top isshown in more detail in FIG. 4 c. Another embodiment of FIGS. 4 a, and 4b include all of the aforementioned features without the drain wire ordrain wire slot, but includes the center hole for strength members. Afurther embodiment of FIGS. 4 a, and 4 b includes all the aforementionedfeatures without the center hole for strength members and without thedrain wire or drain wire slot.

FIGS. 3 d and FIG. 3 f depict the single flap-top in enlarged detail,and FIG. 4 c depicts the double flap-top in enlarged detail. The singleflap-tops (360 and 390) and the double flap-top (410) enclose the wiresor cables within channels created by the separator. Duringmanufacturing, the flap-top is in the opened position and closes aseither pressure or heat or both are applied (normally through a circularcavity during extrusion). Optionally, a second heating die may be usedto ensure closure of the flap-top after initial extrusion of theseparator or cable during manufacture. Another possibility is the use ofa simple metal ring placed in a proper location that forces the flap-topdown during final separator or cable assembly once the conductors havebeen properly inserted into the channels. The metal ring may be heatedto induce proper closure. Other techniques may also be employed as themanufacturing process will vary based on separator and cablerequirements (i.e. no. of conductors required, use of grounding wire,alignment within the channels, etc.). In one embodiment the singleflap-top (360) is secured to a recessed portion of one side of anopening of the cavity of the separator (365), and closure occurs whenthe unsecured, physically free end is adjoined to and adhered with theother end of the outer surface of the channel wall. In anotherembodiment the single flap-top (390) is secured by overlapping andadhering the unsecured end to the outer surface of the separator (395),thereby, enclosing the channel. The double-flap top arrangement requiresthat both flap-top ends physically meet and eventually touch to secureenclosure of the existing cavity (460) formed by the separator (470).

FIG. 5 is a cross-section of another embodiment of the flap-topanvil-shaped separator. Each channel is enclosed by double flaps thatcan be sealed via heat and/or pressure (510, 512, 514, and 515). Eachchannel contains at least one fiber (520, 522, 524, and 526) that runsthe length of the cable. More than one fiber may be included in eachchannel if necessary. The separator also includes a slot for a drain orearthing wire (530). For applications such as multimedia cables, theapplication may have one or more twisted pair, one or more fiber opticconductors, or coaxial cables within the clearance channels of the anvilseparators.

FIG. 6 is a cross-section of a cable that contains four anvil-shapedseparators (602, 604, 606, and 608) within a larger anvil-shapedseparator (610). The larger separator contains a cavity in the center ofthe separator for a strength member (620). Each of the smallerseparators contained within the larger anvil-shaped separator has fourchannels (630, 632, 634, and 636). As shown, each of these channelscontains a twisted pair within this embodiment (640, 642, 644, and 646).This embodiment allows for a total of sixteen twisted pairs to beincluded in one cable.

FIG. 7 a is a cross-section of a cable that contains six symmetricalrifled cross separators (700, 701, 702, 703, 704, 705) within a largeranvil shaped separator (710). The larger separator contains a optionalhollow cavity in the center of the separator for an optional strengthmember (720). Each of the smaller separators contained within the largeranvil-shaped separator has four channels (730, 732, 734, and 736).Within each of these channels in one twisted pair (740, 742, 744, and746). This embodiment allows twenty four twisted pairs to be included inone cable.

FIG. 7 b are cross-sections of a cable that contains rifled sixanvil-shaped separators (750, 751, 752, 753, 754, and 755) within alarger anvil-shaped separator (710). The larger separator contains anoptional hollow cavity in the center of the separator for a either astrength member or an additional conductor pair (725) which is accessedvia a slit (726) which can be forced opened during manufacture. Each ofthe smaller separators contained within the larger anvil-shapedseparator has four smooth or rifled channels (780, 782, 784, and 786).Within each of these channels is one twisted pair (760, 762, 764, and766). This embodiment allows twenty four twisted pairs to be included inone cable. Feature (750) is an optional wired slot for a drain wire withor without a shield.

FIGS. 8 a and 8 b depict a cross-section and additional embodiment of ananvil-shaped separator which has been substantially trimmed such thatthe each edged end of each anvil is removed (800 and 802) to reduceweight resulting in enlarged channel openings (804). FIG. 8 b depictsthe cross-section with optional drain wires within each solid andtrimmed anvil section (810, 812, 814, and 816) as well as optionalrifled slots (820) within each clearance channel and optional asymmetricconductor pair offset due to the skewed elongated axis.

FIG. 9 is a cross-section and additional embodiments of a separatorwhere the dual lobed ends of the anvil are minimized (900 and 902) suchthat an even further reduction in weight, enlarged channel openings(904) and enlarged channel girth are provided. FIG. 9 also includesearthing or drain wire slots (910, 912, 914, and 916).

FIG. 10 is a cross-sectional end view of a large cable space separatorthat itself separates six (6) anvil shaped separators as described indetail and shown in FIGS. 1 and 2 and very similar to the design shownas FIGS. 7 a and 7 b. This separator has an optional center (1000)orifice that allows for reduction of mass and thereby reduction of flamespread and smoke generation in, for example UL 910/NFPA 262/IEC60332-3B₁/IEC 60332-3B₂ and associated flame testing as previouslydescribed. The entire center section (with the center (1000) orifice orwithout it) could be either solid or foamed or a combination using askimmed solid surface over a foamed core. This design allows for sixsolid anvil shaped cores (1001) with four clearance channels forconductor pairs. In addition, the large cable spacer separator includessix special “Y” shaped channel spacings (1002–1007) at the outer edgesthat allow for a fifth conductor pair within these channels. The fifthconductor pairs (1008) are optional in that some or none of the “Y”shaped channel spacings (1002–1007) may be filled. Each of the solidanvil cores (1001) also may optionally contain a center orifice (1009).Each of the conductors consist of an inner solid metal portion (1011,1015, 1018, and 1021) and an outer insulation (1010, 1014, 1017, and1020) covering the solid and metal portion of the conductors orconductor pairs that are held within each of the four clearance channels(1012, 1016, 1019, and 1022) formed by the six anvil shaped separatorscores (1001). In addition to the clearance channels (1012) provided forthe conductors or conductor pairs, there all exists an optionalspecially designed slot (1013) for a metal drain wire that providesproper grounding or earthing of the conductors within the cable forinstances where an aluminum mylar shield may be used.

FIG. 11 is a cross-sectional view of a optionally skewed or asymmetrical“maltese cross-type” cable spacer separator. It is skewed in the sensethat along one axis of symmetry in a two-dimensional plane, thetip-to-tip length is longer than along the other. This spacer providestwo relatively larger width blunt tipped ends (1100) and two relativelysmaller width tipped blunt ends (1102). The distance between a largerwidth blunt end tip and a smaller width blunt end tip along the longeraxis of symmetry provides two skewed channels (1106) for “worst” pairconductors. These pairs are the ones determined to have the leastdesirable electrical properties and thus are intentionally spacedfurther apart form each other. The better performing electrical pairsare contained in two skewed channels (1104) formed between a largerwidth blunt end tip (1100) and a smaller width blunt end tip (1102)along the shorter axis of symmetry. In this manner the “worst pair”channels (1106) are adjacent to the “better pair” channels (1104) sothat the influence of the poorest electrical performing conductors orconductor pairs (1110) are insulated from another poorest or poorerperforming electrical pair (1110). Best or better conductor pairs (1112)would be provided in the better pair channels. As previously alluded to,distance, and the presence of air are the two controllable parametersused in the present invention to reduce electrical propertydeterioration due to “worst pair”—“worst pair” interaction. A center(optional) orifice (1108) is also provided which would allow forreduction of weight of material and better flammability and smokegeneration properties as previously described.

FIG. 12 a is a cross-sectional view of an optionally skewed “maltesecross-type” cable spacer separator with “rifled” sections along theouter perimeter of the spacer separator. It optionally skewed in thesense that along one axis of symmetry in a two-dimensional plane, thetop-to-tip length is longer than along the other. This spacer providesfour equi-widthed blunt tipped ends (1200). The rifled sections as shownin FIG. 12 b contain interstitial stepped optionally rifled spacers(1201) extending from near the blunt tipped ends toward channels (1205)formed for single or paired conductors that are provided such that theconductor or conductor pairs will be “squeezed” into a portion of therifled section where some traction or friction within these interstitialstepped spacer rifled sections will control spacing and movement duringthe entire cabling operation. In this manner, again “worst pair” spacingcan be achieved. A center (optional) orifice (1204) is also providedwhich would allow for reduction of weight of material and betterflammability and smoke generation properties as previously described.

FIG. 13 a is a cross-sectional view of a diamond shaped cable spacerseparator that is solid (1300) and provides for four semi-circularchannels (1310) formed by curved surfaces of the diamond shaped spacerfor conductors. The solid diamond shaped spacer has curved ends thatconverge at each of four tips (1320) which designate the beginning orending of the channels. Individual conductors (1325) would be preferablyplaced in each of the channels for pair separator. Alternatively,conductor pairs could also be separated using this design and technique.

FIG. 13 b is a cross-sectional view of a diamond shaped cable spacerseparator that has a hollowed center circular orifice section (1330) andprovides for four semi-circular channels (1310) formed by curvedsurfaces of the diamond shaped spacer for conductors. The solid diamondshaped spacer has curved ends that converge at each of four tips (1320)which designate the beginning or ending of the channels. Individualconductors would be preferably placed in each of the channels for pairseparator. Alternatively, conductor pairs could also be separated usingthis design and technique.

FIG. 13 c is a cross-sectional view of a diamond shaped cable spacerseparator that has two triangular hollowed center sections, one of whichis an upright equilateral triangular hollowed orifice (1340) and theother of which is a downward-facing equilateral triangular orifice(1345) and provides for four semi-circular channels (1310) formed bycurved surfaces of the diamond shaped spacer for conductors. The soliddiamond shaped spacer has curved ends that converge at each of four tips(1320) which designate the beginning or ending of the channels.Individual conductors would be preferably placed in each of the channelsfor pair separator. Alternatively, conductor pairs could also beseparated using this design and technique.

FIG. 13 d is a cross-sectional view of a diamond shaped cable spacerseparator that has a diamond shaped hollowed center orifice section(1350) and provides for four semi-circular channels (1310) formed bycurved surfaces of the diamond shaped spacer for conductors. The soliddiamond shaped spacer has curved ends that converge at each of four tips(1320) which designate the beginning or ending of the channels.Individual conductors would be preferably placed in each of the channelsfor pair separator. Alternatively, conductor pairs could also beseparated using this design and technique.

FIG. 14 is a cross-sectional view of a pendulum-like shaped cable spacerseparator with a circular-disc like pendant portion (1400) that iseither in the center of the pendulum-like shaped separator or isoptionally skewed to an elongated rectangular shaped end (1410). Thisseparator does not form specific channels for conductors or conductorpairs, however the circular-disc like portion (1400) provides a devicewhich allows for proper spacing of better or worse performing electricalpairs by placing this circular-disc in a specific location. Thecircular-disc (1400) includes an optional center hollow orifice portion(1420), again to reduce material loading which should enable certaincable constructions to pass stringent flame and smoke test requirements.

FIG. 15 is a cross-sectional view of a pendulum-like shaped cable spacerseparator with an elliptical-disc like pendant portion (1500) that iseither in the center of the pendulum-like shaped separator or isoptionally skewed to an elongated rectangularly shaped end (1510). Thisseparator also does not form specific channels for conductors orconductor pairs, however the elliptical-disc like pendant portion (1500)provides a device which allows for proper spacing of better or worseperforming electrical pairs by placing this elliptical-disc in aspecific location. The elliptical-disc like pendant portion (1500)includes an optional center hollow orifice portion (1520), again toreduce material loading which should enable certain cable constructionsto pass stringent flame and smoke test requirements.

FIG. 16 is a cross-sectional view of a pendulum-like shaped cable spacerseparator with a diamond-disc like pendant portion (1600) that is eitherin the center of the pendulum-like shaped separator or is optionallyskewed to an elongated rectangularly shaped end (1610). This separatorforms more specific channels for conductors or conductor pairs (1625)than that of FIGS. 14 and 15, and the diamond-disc like portion (1600)additionally provides a device which allows for proper spacing of betteror worse performing electrical pairs by placing this diamond-disc in aspecific location. The diamond-disc like portion (1600) includes anoptional center hollow orifice portion (1620), again to reduce materialloading which should enable certain cable constructions to passstringent flame and smoke test requirements. The design and function ofthe separator of FIG. 16 is similar to that shown in FIGS. 13 a– 13 dwith the additional feature of the horizontal separator bar thatrestricts movement of the conductors in the vertical direction duringcabling and subsequent handling.

FIG. 17 is a cross-sectional view of a pendulum-like, dual-lobed shapedcable spacer separator with a diamond-shaped pendant portion in thecenter that can be optionally skewed to one end and with lobed endportions (1700). Channels for conductors (1725) are formed by curvedelongated rectangular portions (1710) of the dual-lobbed pendulum-likeshaped separator). This separator forms more specific channels forconductors or conductor pairs (1725) than that of FIGS. 14 and 15,similar to that of FIG. 16, and the diamond-shaped pendant portionadditionally provides a device which allows for proper spacing of betteror worse performing electrical pairs by placing this diamond-shapedpendant in a specific location. The diamond-shaped pendant sectionincludes an optional center hollow orifice portion (1720), again toreduce material loading which should enable certain cable constructionsto pass stringent flame and smoke test requirements.

FIG. 18 is a cross-sectional view of a rifled and symmetrically balancedcross cable spacer separator (1800) that is comprised optionally of asolid, foamed or solid skin over a foamed core as described earlier inthe present specification and again for FIG. 18. The rifled crossseparator also is comprised of four “tipped” ends that have key-likefeatures (1810). The rifled cross separator provides clearance channelsfor conductors or conductor pairs that may or may not be separatelyinsulated (1825) where each conductor or conductor pair includes anouter insulation material (1835) and an inner section portion of theconductor (1830). As for most of the prior separator constructions, ahollow orifice in the center (1820) is optional again for the purpose ofmaterial reduction loading.

FIG. 19 is a cross-sectional view of a dual drill-bit shaped cablespacer separator (1900) or “mirrored battleship” shape that is comprisedoptionally of a solid, foamed or solid skin over a foamed core asdescribed earlier. If one were to split this separator along its centralhorizontal axis, the top and bottom portions would be mirrored images ofeach other in that the bottom portion would appear as a reflection ofthe top portion in much the way a battleship would be reflected byfloating in a still body of water. Along the top portion of theseparator, there is an ascending stepped section (1905) upon whichexists a key-like shaped section (1910) that includes a double key-wayinward protruding portion (1911) and a double key-way outward protrudingportion (1912) of the separator. Along the bottom portion of theseparator, there is a symmetrical (with the top portion) descendingstepped section (1905) which includes the same shaped key-like section(1910) with inward protruding portions (1911) and outward protrudingportions (1912) that exist under the bottom stepped section (1905).

This separator again provides at least a four quadrant set of clearancechannels for conductors or conductor pairs with an optional outer film(1930) and with conductors that have both an outer insulation material(1940) and an inner conductor material (1945) for each individualconductor or conductor pair. There is a center hollow portion (1950) aspart of the stepped (1905) portion that is also shaped in a circularfashion to again achieve material reduction for cost, flammability andsmoke generation benefits.

FIG. 20 is a cross-sectional view of a “staggered rifled cross” shapedcable spacer separator (2000) that is comprised optionally of a solid,foamed or solid skin over a foamed core. As in the spacer of FIG. 19,there is at least one upward protruding sections (2005) near the centerportion of the staggered rifled cross separator along the lateral orhorizontal direction that are longer than such subsequent upwardprotruding sections in the same direction. There is also at least onelaterally protruding section (2006) near the center portion of thestaggered rifled cross separator along the lateral or horizontaldirection that is longer than any subsequent laterally protrudingsection in the same direction. In addition, there are inwardly intrudingsections near the center portion of the spacer (2007) along the verticaland lateral or horizontal directions of the separator as well aslaterally protruding sections (as many as four) (2008) that may existnear the center portion of the staggered rifled cross separator.Inwardly intruding sections are also located near the tipped portions ofthe separator (2009)—as many as four may exist. At the same tipped endportion, there may be inverted ends (2010). This entire geometry isconfigured to ensure that “worst pair” electrical conductors are spacedin a staggered arrangement to ensure that little or no influence orsynergism can occur between the electrically worst two pairs orelectrically worst individual conductors. The rifled arrangement allowsfor squeezing the conductors into the interstices of each of fourquadrants with optional outer jacket or film insulation (2030) for theconductor pairs which include an outer insulation section (2040) and aninner conductor sections (2045). The central portion of the separatormay also include a hollow orifice (2020).

FIG. 21 a is a cross-sectional view of an asymmetric cross, where eachof four quadrants formed by the cross to make clearance channels areformed by either vertical or horizontal sections along an axis of thecross with varying widths. Here, the left side horizontal member (2110)is narrower in width than that of the right side horizontal member(2120). Similarly, the vertical member (2130) extending in an upwarddirection is narrower in width than that of the other vertical member(2140). FIG. 21 b is completely analogous to FIG. 21 a except that theasymmetric cross in this cross-sectional view includes rifled or“saw-blade” like members as shown previously. In this figure, section(2150) is narrower than section (2160) along the horizontal axis, andsection (2170) is narrower than section (2180). The “teeth” of thesaw-blade are described in detail with FIG. 22.

FIG. 22 is a cross-sectional view of a saw-blade type separator (2200)that may be, in fact, a semi-rigid thermoplastic or thermoset film with“serrated” or rifled section along the top and bottom portions of thehorizontal axis. The teeth that form serrated edges may be shaped inseveral ways, two of which are shown in the expanded view of the samefigure. Along either the top or bottom portion of the separator bluntundulating sections may be used (2210) or other shapes such as the “u”or “v” grooved sections (2220). It should be understood that the teethmay be used in any combination desired, based on the need of the cablemanufacturer.

FIG. 23 a is a cross-sectional view of a symmetrical “Z” or angle-ironshaped type separator (2300) that also may be a semi-rigid thermoplasticor thermoset film. As shown, the separator is symmetric in that bothhorizontal sections (2310) and (2320) are of the same length and evenlyspaced apart by the central vertical section (2330). The separator couldalso be asymmetric in that either of the horizontal sections could beextended or shortened with respect to one another. Also, the verticalsection (2330) length could be adjusted as needed for electricalspecification requirements. This separator is provided primarily for 2conductor pair (2340) to be inserted in the clearance channels provided.FIG. 23 b is also a symmetrical “Z” or angle-iron shaped type separatorwith the addition, in this cross-sectional view, of rifled or“saw-blade” like members as shown previously. In this figure, sections(2350) and (2360) along the horizontal axis can be the same length orarbitrarily different lengths—resulting in an asymmetric shape. Thecentral vertical section (2370) and associated saw-blade like teeth canalso be lengthened or shortened as necessary. The “teeth” of thesaw-blade are described in detail in FIG. 22 and the same bluntundulating, “u” or “v” shaped grooves can be used for this separator aswell. This separator is provided primarily for 2 conductor pair (2380)to be inserted in the clearance channels provided.

FIG. 24 a is a cross-section view of one embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region (100) with four extending rifled protrusion (2410,2412, 2414, 2416) each extending in a preferred 90 degree separationfrom each other for optimum pair separation. The optimum pair separationis gained by placing pairs between the four extending rifled protrusionsin regions (2420, 2422, 2424, 2426). The central circular ring portion(2400) optionally includes a hollow region (2430) to act as an air blownfiber (ABF) duct which is available for filling with optical fiber whichis comprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 24 b is a cross-section view of a second embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a, but also includes a second innerring (2440) within the hollow region comprised of a different materialthan the outer ring for either increasing lubricity or friction withfour extending rifled protrusions each extending in a preferred 90degree separation from each other for optimum pair separation.

FIG. 24 c is a cross-section view of a third embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a, but also includes a second innerring within the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections (2450) with four extending rifled protrusions eachextending in a preferred 90 degree separation from each other foroptimum pair separation.

FIG. 24 d is a cross-section view of a fourth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 c, but also includes the optionaluse of a organic or inorganic fibers (2460) including polyamide (forexample Kevlar®) filing and an optional strength member within thesecond inner ring within the hollow region comprised of a differentmaterial than the outer ring as well as allowing for multiple separatemultimode or single mode fiber optic units (2462) also contained withinthe same hollow region with four extending rifled protrusions eachextending in a preferred 90 degree separation from each other foroptimum pair separation.

FIG. 24 e is a cross-section view of a fifth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 b and also includes an inner pulltape (2470) for attaching optical fibers or metallic conductors whereinthe tape optionally itself incorporates a grip or for which a grip isprovided for future pulling of those communication media through thehollow region at some future time or during an installation with fourextending rifled protrusions each extending in a preferred 90 degreeseparation from each other for optimum pair separation.

FIG. 24 f is a cross-section view of a sixth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 b but also two individual conductors(2480 and 2482) (which may be twisted) inside the second inner ringwhich is smooth instead of rifled within the hollow region and comprisedof a different material than the outer ring as well as allowing formultiple separate multimode or single mode fiber optic units alsocontained within the same hollow region with four extending rifledprotrusions each extending in a preferred 90 degree separation from eachother for optimum pair separation.

FIG. 24 g is a cross-section view of a seventh embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a with four extending rifledprotrusions each extending in a preferred 90 degree separation from eachother for optimum pair separation, but also includes the optionaladdition of one or more coaxial conductors (2490) with a tinned copperbraided shield (2492).

FIG. 25 a is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 24 a but possesses 6 instead of 4rifled protrusions (2510, 2512, 2514, 2516, 2518, 2520) each extendingin a preferred degree separation from each other for optimum pairseparation. The optimum pair separation is gained by placing pairsbetween the six extending rifled protrusions in regions (2530, 2532,2534, 2536, 2538, and 2540). The central circular ring portion (2500)optionally includes a hollow region (2550) to act as an air blown fiber(ABF) duct which is available for filing with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 25 b is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 25 a with as few as two and as many assix extending protrusions each extending in a preferred degreeseparation along the outer ring from each other for optimum pairseparation, but also includes a second inner ring within the hollowregion comprised of a different material than the outer ring forincreasing friction utilizing rifled inner spatially arranged sections(2560).

FIG. 25 c is a cross-section view of another embodiment of the cablesupport-separator separator that includes the same symmetrical core witha central circular ring region as for FIGS. 25 a and 25 b but with aninner smooth ring section (2570) with as few as two and as many as sixextending protrusions each extending in a preferred degree separationalong the outer ring from each other for optimum pair separation thatoptionally includes the optional addition of one or more conductors(2574) including optionally organic or inorganic fibers such aspolyamide (for example Kevlar®) filling and an optional strength member(2572) within the second inner ring.

FIG. 25 d is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 25 a and 25 c but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filing andan optional strength member within the second inner ring. Also, betweenas few as one and as many as six of the extending projections,additionally daisy-like spacers (2580)(as shown in FIG. 28 a) are placedwhich themselves allow for spacing of individual conductors or conductorpairs (2582).

FIG. 25 e is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 25 a and 25 c but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filing an anoptional strength member within the second inner ring. Also, between asfew as one and as many as six of the extending projections are shownwithout (2584) the additional daisy-like spacers (FIG. 28 a).

FIG. 25 f is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 25 e but with an inner smooth ringsection with as few as two and as many as six extending protrusions eachextending in a preferred degree separation along the outer ring fromeach other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring. Also, betweenas few as one and as many as six of the extending projections,additional spacers (2590) comprised of a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable designed (as shown in FIG.29 e) are placed which themselves allow for spacing of individualconductors or conductor pairs.

FIG. 26 a is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region (2600) with four extending smooth protrusions(2610, 2612, 2614, 2616), each protrusion extending less than those ofFIGS. 24 a through 25 f, each again extending in a preferred 90 degreeseparation from each other for optimum pair separation. The centralregion portion optionally includes a hollow region (2620) to act as anair blown fiber (ABF) duct which is available for filing with opticalfiber which is comprised of solid, semi-solid, foamed or hollowpolymeric smooth internal and external surfaces.

FIG. 26 b is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 24 a through 24 f, eachagain extending in a preferred 90 degree separation from each other foroptimum pair separation and also includes a second inner ring (2630)within the hollow region comprised of a different material than theouter ring for either increasing lubricity or friction. The central ringportion optionally includes a hollow region to act as an air blown fiber(ABF) duct which is available for filing with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 26 c is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 24 a through 25 f, eachagainst extending in a preferred 90 degree separation from each otherfor optimum pair separation and also includes also includes a secondinner ring within the hollow region comprised of a different materialthan the outer ring for increasing friction utilizing rifled innerspatially arranged sections (2640). The central ring portion optionallyincludes a hollow region to act as an air blown fiber (ABF) duct whichis available for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIGS. 26 d and 26 e are cross-section views of another embodiment of thecable support-separator that includes a symmetrical core with a centralcircular ring region with as few as two (2670 and 2672 in FIG. 26 e) andas many as six extending smooth protrusions (2650, 2652, 2654, 2656,2658, 2660 in FIG. 26 d), each protrusion extending less than those ofthe series of FIGS. 24 a through 25 f, each again extending in apreferred separation from each other for optimum pair separation andalso includes also includes a an optional second inner ring within thehollow region comprised of a diffferent material than the outer ring forincreasing friction utilizing rifled inner spatially arranged sections.The central ring portion optionally includes a hollow region to act asan air blown fiber (ABF) duct which is available for filling withoptical fiber which is comprised of solid, semi-solid, foamed or hollowpolymeric smooth internal and external surfaces.

FIG. 26 f is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with no extending protrusions (2680) that includesalso an optional second inner ring within the hollow region comprised ofa different material than the outer ring for increasing frictionoptionally utilizing rifled inner spatially arranged sections. Thecentral ring portion optionally includes a hollow region to act as anair blown fiber (ABF) duct which is available for filing with opticalfiber which is comprised of solid, semi-solid, foamed or hollowpolymeric smooth internal and external surfaces.

FIG. 27 a is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region (2700) with four extending protrusions (2710, 2712,2714, 2716) each protrusion extending less than those of FIGS. 24 athrough 25 f and each with at least a single cross-like section (2720,2722, 2724, 2726) extending outward from the circular ring section in apreferred 90 degree separation from each other for optimum pairseparation. The central ring portion optionally includes a hollow region(2730) to act as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 27 b is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of FIGS. 24 a through 25 f, each again extending in apreferred 90 degree separation from each other for optimum pairseparation and also includes a second inner ring (2740) within thehollow region comprised of a different material than the outer ring foreither increasing lubricity or friction. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filing with optical fiber which is comprisedof solid, semi-solid, foamed or hollow polymeric smooth internal andexternal surfaces.

FIG. 27 c is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of FIGS. 24 a through 25 f, each again extending in apreferred 90 degree separation from each other for optimum pairseparation and also includes a second inner ring within the hollowregion comprised of a different material than the outer ring for eitherincreasing lubricity or friction. The inner portion of the hollow ringregion here is optionally filled with inorganic or organic fibers (2750)such as polyamide fiber (Kevlar®) and at least four single or multimodefiner optic units (2760, 2762, 2764, and 2766).

FIGS. 27 d and 27 e include a cross-section view of another embodimentof the cable support-separator that includes a symmetrical core with acentral circular ring region with as few as two (2770 and 2772 in FIG.27 e) and as many as six (2750, 2752, 2754, 2756, 2758, and 2760 in FIG.27 d) extending protrusions each with at least a single cross-likesection, each protrusion extending less than those of FIGS. 24 a through25 f, each again extending in a preferred separation from each other foroptimum pair separation and also includes an optional second inner ringwithin the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections. The central ring portion optionally includes a hollowregion to act as an air blown fiber (ABF) duct which is available forfiling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smoother internal and external surfaces.

FIG. 27 f includes a cross-section view of another embodiment of thecable support-separator includes a symmetrical core with a centralcircular ring region with no extending protrusions (2780) that includesalso an optional second inner ring which is smoother within the hollowregion comprised of a different material than the outer ring forincreasing friction as well as allowing for multiple separate multimodeor single mode fiber optic units (2785) also contained within the samehollow region. The central ring portion optionally includes a hollowregion to act as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 28 a is a cross section view of another embodiment of the cablesupport-separator that includes a hollow four-petal (2810, 2812, 2814,and 2816) or “daisy” shaped arrangement with a central core (2800) thatmay or may not be hollow (2820 shown hollow). If the central region ishollow, the possibility again exists for that region to act as an airblown fiber (ABF) duct which is available for filling with opticalfiber. Coaxial or twisted pair conductors may also be introduced in thatregion.

FIG. 28 b is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal (2840, 242, 2844, and2486) or “daisy” shaped arrangement with a central core (2830) that mayor may not be hollow (2832 shown hollow). Each “petal” contains twohollow sections (2850 and 2852) for additional optical or metallicconductor media. The central region (2832) is hollow allowing for thepossibility that this region may act as an air blown fiber (ABF) ductwhich is available for filing with optical fiber. Coaxial or twistedpair conductors may also be introduced in that region.

FIG. 28 c is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core (2860) that may or may not be hollow.Each “petal” contains three hollow sections (2870, 2872, 2874) ofdiffering diameters for additional optical or metallic conductor media.The central region (2860) is solid.

FIG. 28 d is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that mayor not be hollow. Each “petal”contains three hollow sections of differeing diameters for additionaloptical or metallic conductor media. In this case, the center hollowsection of each petal is filled with an optical fiber unit (2880). Thecentral region is solid or optionally hollow.

FIG. 28 e is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that mayor may not be hollow. Each“petal” contains three hollow sections of differeing diameters foradditional optical or metallic conductor media. In this case, the centerhollow section of the daisy is filled with an optical fiber unit (2890).The central region is solid or optionally hollow.

FIGS. 29 a, 29 b, 29 c are cross-sectional views of another set ofembodiments of the cable support-separator that includes a circular ringregion (2900) which is surrounded by rounded lobes (2910, 2912, 2914,2916) in a symmetric diamond-like geometry that defines as many as fourseparate regions for pairs that are properly separated in the final(often jacketed) cable design. Again the central ring portion canoptionally include a hollow region (2920) that may be used as an airblown fiber (ABF) duct which is available for filling with optical fiberwhich is comprised of solid, semi-solid, foamed or hollow polymericsmooth internal and external surfaces. FIG. 29 a has no inner ring. FIG.29 b has a smooth inner ring (2930) with optionally different materialthan the outer ring, and FIG. 29 c has an inner ring (2940) with rifledsections (2942). Each can optionally be used for coax or twisted pair aswell as for fiber optic conductors in advance, during, or afterinstallation.

FIG. 29 d is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes the optional addition of one or more conductors includingoptionally organic or inorganic fibers such as polyamide (for exampleKevlar®) filling and an optional strength member (2950) within thesecond inner ring (that may or may not be rifled). Again the centralring portion can optionally include a hollow region that may be used asan air blown fiber (ABF) duct which is available for filling withoptical fiber (2960, 2962, 2964, 2966) which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 29 e is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion filled with a fiber optic unit (2970) as wellas four separated conductor pairs (2980, 2982, 2984, 2986) in each ofthe regions defined by the symmetric diamond-like geometry of the cablesupport-separator. Again the central ring portion can optionally includea hollow region that may be used as an air blown fiber (ABF) duct whichis available for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 29 f is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion with a second inner ring portion (2990) filledwith a fiber optic unit (2992) or other conductors as well as fourcross-like separators (2994) (see FIG. 18) in each of the regionsdefined by the symmetric diamond-like geometry of the cablesupport-separator within which another, up to four pairs of conductors(2996) are situated and separated by the cross-like separator. Again thecentral ring portion can optionally include a hollow region that may beused as an air blown fiber (ABF) duct which is available for fillingwith optical fiber which is comprised of solid, semi-solid, foamed orhollow polymeric smooth internal and external surfaces.

FIG. 30 a is a cross-section view of another embodiment of the cablesupport-separator that includes a more conventional cross-like separatorsection (3000) with “rifled” sections (3002 and 3004, for example)extending outward into four quadrants (3010, 3012, 3014, 3016) away fromthe central region (3000) and is encased or covered within an outerinsulated layer (3020) which is itself shaped in an identical crossexcept that the dimensions of this outer cross is larger than the rifledinner cross and functions as a “skin”. The inner cross-like portion maybe metallized by utilizing electroless or electrolytic platingtechniques over a thermoplastic film.

FIG. 30 b is a cross-section view of another embodiment of the cablesupport-separator that includes the same more conventional cross-likeseparator section as with FIG. 30 a except that this separator containsa shield (3030) that extends along the horizontal axis and optionallyalso along the vertical axis or both axes within the horizontal hollowportion (3040) of the cross-like separator. This shield is comprised ofaluminum PET film and may be configured so that it is held within theouter cross-like separator (3020) and may also be part of an overallshielded cable which is shielded using aluminum backed PET film or abraided metallic shield or any combination.

FIG. 31 a is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “zig-zag” extensions (3110, 3112, 3114, forexample) that extend away from the central region (3100). Again thecross-like “zig-zag” arrangement may be covered within an outerinsulated layer which is itself shaped in an identical cross except thatthe dimensions of this outer cross are larger than the rifled innercross and functions as a “skin”. This design optionally includes fourseparated conductor pairs (3120, 3122, 3124, 3126) in each of theregions defined by the symmetric diamond-like geometry of the cablesupport-separator.

FIG. 31 b is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “sickle-like” extensions (3130, 3132, 3134, 3136)that extend away from the central region. Again the cross-like andsickle-like sections arrangement may be covered within an outerinsulated layer which is itself shaped in an identical cross except thatthe dimensions of this outer cross are larger than the rifled innercross and functions as a “skin”. This design optionally includes fourseparated conductor pairs (3120, 3122, 3124, 3126) in each of theregions defined by the symmetric diamond-like geometry of the cablesupport-separator.

FIG. 32 is a cross-sectional view of another embodiment (3200) withseveral hollow regions (3210, 3212, 3214, for example) for blown fiberor any transmission media for present, future, or concurrentinstallations using the support-separator alone or in combination with acable.

FIGS. 33 a and 33 b are cross-sectional views of another set ofembodiments of the cable support-separator that includes a circular ringregion (3300) which is surrounded by semi-rounded lobes (3310, 3312,3314, 3316) in a symmetric star-like geometry that defines as many asfour separate regions for pairs (3320, 3322, 3324, 3326) that areproperly separated in the final (often jacketed) cable design. Again thecentral ring portion can optionally include a hollow region (3330) thatmay be used as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces. FIGS.33 a and 33 a include view of optionally filled inner hollow regionssuch that each can optionally be used for coax or twisted pair as wellas for fiber optic conductors (in advance, during or afterinstallation). FIG. 33 a includes a view of this design including theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring (that may ormay not be rifled). FIG. 33 b includes a view of this design thatincludes the optional addition of coaxial cable (3302) in the hollowcenter region. The central circular region (3301) is of a slightlylarger size that that shown in FIG. 33 a in order to allow for coaxialcable in the central hollow region of the separator.

It will, of course, be appreciated that the embodiment which has justbeen described has been given simply by the way of illustration, and theinvention is not limited to the precise embodiments described herein,various changes and modifications may be effected by one skilled in theart without departing from the scope or spirit of the invention asdefined in the appended claims.

1. A high performance communications cable comprising: an interiorsupport-separator with an external radial and axial surface, saidinterior support-separator extending along a longitudinal length of saidcommunications cable, said interior support-separator also having acentral region, said central region also extending along a longitudinallength of said interior support-separator of said communications cable;said interior support-separator comprising one or more outwardlyextended shaped protrusions and conduit tube disposed in said centralregion; wherein said central region, outwardly extended protrusions, andconduit tube are comprised of a composition of inorganic and organicpolymer; said composition including: fluorinated ethylene propylene,fluorinated ethylene, chlorinated ethylene propylene, fluorochlorinatedethylene, perfluoroalkoxy, fluorochlorinated propylene, a copolymer oftetrafluoroethylene and perfluoromethylvinylether (MFA), or a copolymerof ethylene and chlorotrifluoroethylene (ECTFE); and homo or copolymersof ethylene or propylene with fluorinated ethylene or polyvinylidenefluoride (PVDF); and blends of polyvinyl chloride, polyvinylidenechloride, nylons, polyesters, polyurethanes; and nano-composites of clayincluding unsubstituted or substituted fullerenes primarily comprised ofC₆₀ molecules; and nano-sized particles of ZnO or TiO₂.
 2. The highperformance communications cable or interior support-separator of claim1, wherein said interior support-separator, said central region, saidoutwardly extended protrusions and said conduit tube are capable ofshielding conductors that transmit data at 10 Gbit while substantiallymitigating or eliminating all forms of crosstalk.
 3. The highperformance communications cable of claim 1 or interiorsupport-separator, wherein said composition also comprises acid gasscavengers including hydrogen chloride or hydrogen fluoride or otherhalogenated gasses that scavenge gasses during combustion.
 4. The highperformance communications cable or interior support-separator of claim1, wherein said composition includes the use of recycled or regroundthermoplastics in an amount up to 100%.
 5. The high performancecommunications cable or interior support-separator of claim 1, wherein aratio of said fluorinated or otherwise halogenated polymers orcopolymers to said ethylene or vinyl chloride polymers or copolymers isfrom 0.1% up to 99.9%.
 6. The high performance communications cable ofclaim 5, wherein said composition is a foamed polymer and furtherincludes a nucleating agent of polytetrafluoroethylene, carbon black,color concentrate, or boron nitride or other acceptable nucleating orblowing agent.
 7. The high performance communications cable of claim 1,wherein said composition of said interior support-separator, saidcentral region, said outwardly extended protrusions and conduit tubecomprises solid, partially solid, or foamed material, or a solid skinsurface over the foamed material.
 8. The high performance communicationscable or interior support-separator of claim 1, wherein said interiorsupport-separator and said central region includes anvil shaped coresupport-separator sections.
 9. The high performance communications cableor interior support-separator of claim 8, wherein each of saidanvil-shaped core support-separator sections comprises channel wallsdefining said one or more clearance channels and where said clearancechannels are defined by a semi-circular geometry such that there remainsa 180 degree opening along an external radial and axial surface of saidinterior support.
 10. The high performance communications cable orinterior support-separator of claim 9, wherein each of said anvil-shapedcore support-separator sections comprises clearance walls defined by asemi-closed semi-circular geometry such that there remains less than a160 degree opening along said exterior radial and axial surface, butmore than a 10 degree opening along said external surface of saidinterior support-separator of said clearance channels.
 11. The highperformance communications cable or interior support-separator of claim8, wherein each of said anvil-shaped core support-separator sectionscomprises clearance walls defined by a fully closed circular geometrythat remains closed and includes a flap-top allowing for opening orenclosing said exterior radial and axial surfaces of said channel wallsof said clearance channels.
 12. The high performance communicationscable or interior support-separator of claim 11, wherein said flap-topis comprised of a press-fit arrangement that is hinged allowing foropening and enclosing said exterior radial and axial surfaces of saidchannel walls of said clearance channels.
 13. The high performancecommunications cable or interior support-separator of claim 11, whereinsaid flap-top is sealed by use of heat, tape, interlocking, or by skinextrusion of said hinged press-fit arrangement.
 14. The high performancecommunications cable or interior support-separator of claim 11, whereineach of said anvil-shaped core support-separator sections comprises saidclearance walls defined by a fully closed circular geometry that remainsclosed including an interlocking double flap-top, where said doubleflap-top is adhered to or adjoined with a surface of each side of saidclearance walls for opening or closing said exterior radial and axialsurfaces of said channel walls of said clearance channels.
 15. The highperformance communications cable or interior support-separator of claim14, wherein said double flap-top is comprised of a press-fit arrangementon each end that remains in an opened or closed position for saidexterior radial and axial surfaces of said channel walls of saidclearance channels.
 16. The high performance communications cable orinterior support-separator of claim 14, wherein said channel wallscomprise interior surfaces that are corrugated including internal axialgrooves separated by a sufficient distance such that individualconductors or conductor pairs maintain required electrical integrity andsuch that said conductor or conductor pairs are forced against an edgeof said grooves or sections of said channel walls.
 17. The highperformance communications cable or interior support-separator of claim16, wherein said channel walls comprise interior surfaces that arecorrugated including internal axial grooves separated by a sufficientdistance such that individual conductors or conductor pairs forced intosaid grooves maintain required electrical integrity.
 18. The interiorsupport-separator of claim 16, wherein said channel walls compriseinterior surfaces that are corrugated including internal axial groovesseparated by a sufficient distance such that individual conductors orconductor pairs maintain required electrical integrity and such thatsaid conductors or conductor pairs are forced against an edge of saidgrooves or sections of said channel walls.
 19. The interiorsupport-separator of claim 18, wherein said channel walls compriseinterior surfaces that are ribbed including internal radial groovesseparated by a sufficient distance such that individual conductors orconductor pairs maintain required electrical integrity.
 20. The interiorsupport-separator of claim 16, wherein said interior support-separatorcomprises a convoluted external radial and axial surface extending alonga longitudinal length such that external surfaces of said anvil shapedcore support-separator section include external radial grooves alsoextending along
 21. The interior support-separator of claim 14, whereinsaid double flap-top is sealed by use of heat, tape, or an interlockingpress-fit arrangement. said longitudinal length of said interiorsupport-separator such that said interior support-separator itselffunctions as a cable jacket.
 22. The high performance communicationscable or interior support-separator of claim 8, wherein said interiorsupport-separator comprises a corrugated or convoluted external radialand axial surface extending along a longitudinally length of saidcommunications cable, such that external surfaces of said anvil shapedcore support-separator sections include external radial grooves alsoextending along said longitudinal length of said core support-separatorsuch that said interior support-separator can itself function as a cablejacket for said communications cable.
 23. The high performancecommunications cable or interior support-separator of claim 8, whereineach of said anvil shaped core support-separator sections are singularlyfilled with individual or paired metallic or coaxial electricaltransmitting conductors or optical fiber conductors, or filled with acombination of said individually or paired metallic or optical fiberconductors along said longitudinal length of said support and saidcable.
 24. The high performance communications cable or interiorsupport-separator of claim 8, wherein at least one anvil shapedsupport-separator section comprises a slotted section distinct from saidanvil shaped support-separator sections that is sufficient to contain agrounding wire with a shielding tape.
 25. The interior support-separatorof claim 8, wherein at least one anvil shaped support-separator sectioncomprises rounded edges of said anvil shaped support-separator sectionsat an outer radial end of said anvil shaped support-separator sectionssufficient to reduce overall weight and size of said interiorsupport-separator and subsequently said cable.
 26. The interiorsupport-separator of claim 8, wherein at least one anvil shapedsupport-separator sections comprises minimized dual lobes at an outerradial end of said anvil shaped support-separator sections sufficient tominimize and reduce overall weight and size of said anvil shapedsupport-separator and subsequently said cable.
 27. The interior supportof claim 8, wherein said anvil shaped core support-separator sectionsare twisted to a specified lay length.
 28. The high performancecommunications cable or interior support-separator of claim 1, whereinsaid interior support-separator comprises a center portion, wherein saidcenter portion of said interior support-separator is hollow or solidalong a longitudinal length of said communications cable.
 29. The highperformance communications cable or interior support of claim 1, whereinsaid metal conductors are copper with or without metallic shielding. 30.The high performance communications cable or interior support-separatorof claim 1, wherein said metal conductors are aluminum with or withoutmetallic shielding.
 31. The high performance communications cable orinterior support-separator of claim 1, wherein said cable comprises astrength member wherein said strength member lies parallel to saidinterior support-separator inside a communications cable jacket orwithin said hollow portion of said interior support-separator along saidlongitudinal direction of said interior support-separator and saidcable.
 32. The interior support-separator for a communications cable asin claim 1, extending along a longitudinal length of said communicationscable comprising a pendulum shaped separator configuration with acircular disc pendant that comprises a circular central region of saidpendulum shaped separator and a hollow orifice in a central region of acentral portion of said interior support-separator.
 33. The interiorsupport-separator of claim 32, wherein said circular disc pendant isskewed to one end of said central region of said pendulum shapedseparator.
 34. The interior support-separator of claim 32, extendingalong a longitudinal length of said communications cable wherein saidsupport-separator comprises a pendulum shaped configuration with pendantshaped sections being an elliptical disc like shaped pendant thatcomprises a central region of said pendulum shaped separator and ahollow orifice in a center region of said central portion of saidinterior support-separator.
 35. The interior support-separator of claim34, where said elliptical disc like pendant is skewed to one end of saidcentral region of said pendulum shaped separator.
 36. The interiorsupport-separator for a communications cable as in claim 32, extendingalong a longitudinal length of said communications cable comprising apendulum shaped configuration with two ends with a pendant shapedsection comprising a diamond-like shape and a hollow orifice in acentral region of said central portion of said interiorsupport-separator.
 37. The interior support-separator of claim 36, wheresaid diamond-like shape may be nearer either end of said central regionof said pendulum shaped configuration than near said central region. 38.The interior support-separator for a communications cable as in claim32, extending along a longitudinal length of said communications cablecomprising, a dual-lobed shaped pendulum-like configuration with curvedelongated lobed end portions along a top portion and a bottom portion ofsaid pendulum-like configuration creating at least two clearancechannels for conductors or conductor pairs and a hollow orifice in acentral region of said central portion of said interiorsupport-separator.
 39. The interior support-separator for acommunications cable as in claim 1, comprising at least two symmetricalor asymmetrical intersecting arms that intersect in a cross-like manneralong an essentially horizontal and vertical axis; said intersectingarms provided with ladder-like steps evenly spaced along each arm andalong a complete length of said arm whereby each arm with saidladder-like steps forms a rifle-like pattern along said horizontal andvertical axis said intersecting arms providing four or more separateclearance channels and wherein said arms are comprised of solid orfoamed material.
 40. The interior support-separator for a communicationscable as in claim 39, extending along a longitudinal length of a saidcommunications cable, comprising at least two intersecting arms thatintersect in a cross-like manner along an essentially horizontal andvertical axis; said intersecting arms providing ladder-like steps evenlyspaced along each arm and along a complete length of said intersectingarm whereby each arm with said ladder-like steps forms a rifle-likesaw-tooth pattern along said horizontal and vertical axis and; a centralportion at an intersection of said each arm, said central portioncomprising a central solid member that includes step-like portions cutaway from said central solid member and a hollow orifice in a centralregion of said central portion of said interior support-separator andwhere said central region is void of a saw-tooth pattern along at leastone or more of said horizontal and vertical axis.
 41. The interiorsupport-separator for a communications cable as in claim 39, extendingalong a longitudinal length of said communications cable comprisinginstead at least two spatial quadrants defined by a horizontal armmember of said support-separator including a two sided drill-bit likeshaped central member with geometrically symmetric sections in oppositequadrants and; each having a drill-bit like shape that is a mirror imageof the other drill-bit-like shape in the other quadrant and saidsupport-separator in sum appears to be shaped as a mirrored battleshipand a hollow orifice in a center region of said central portion of saidinterior support-separator.
 42. The interior support-separator for acommunications cable as in claim 39, extending along a longitudinallength of said communications cable comprising at least two intersectingarms that intersect in a cross-like manner comprising: a cross likesupport-separator along an essentially horizontal and vertical axis;said intersecting arms providing ladder-like steps evenly spaced alongeach arm and along a complete length of each arm with said ladder-likesteps forming a rifle-like saw-tooth pattern along said horizontal andvertical axis and; a central portion of said two intersecting arms, saidcentral portion comprising a hollow center wherein said vertical andhorizontal intersecting arms are initially wide or narrow along ahorizontal or vertical axis and become finally narrow or wide along samesaid horizontal or vertical axis such that said cross likesupport-separator comprises an asymmetric pattern.
 43. The interiorsupport-separator for a communications cable as in claim 39, extendingalong a longitudinal length of said communications cable comprising atleast two spatial quadrants defined by a horizontal member of saidsupport-separator comprising rifle-like saw-blade tooth sections alongeither a top or bottom portion of said horizontal member.
 44. Theinterior support-separator for a communications cable of claim 43,wherein said horizontal member is comprised of a semi-flexible material,a semi-flexible thermoplastic material, or a semi-rigid thermosetmaterial.
 45. The interior support-separator of claim 43, wherein saidsupport-separator is void of any rifle-like saw-blade sections and issimply a film.
 46. The interior support-separator for a communicationscable as in claim 1, extending along a longitudinal length of saidcommunications cable comprising at least two spatial quadrants definedby two horizontal members connected by a vertical member with two sidessuch that said support-separator appears as a symmetric or skewed angleiron with a z-like shape and where each of said horizontal members islonger, shorter or the same length as said vertical member.
 47. Theinterior support-separator of claim 46, wherein said support-separatorincludes rifle-like saw-blade tooth sections along any or all members ofsaid support-separator and along either side of each member of saidsupport-separator.
 48. The interior support-separator of claim 1,providing a specified lay length by implementing a twisting therebyproviding a lay length twist into said support-separator prior tomanufacturing said final communications cable assembly.
 49. The interiorsupport-separator of claim 1, wherein said support-separator comprises24 pair of electrical conductors and a twenty fifth pair of electricalconductors wherein said twenty fifth pair is placed within an orificewithin said central region of said interior support-separator.
 50. Thehigh performance communications cable of claim 1 comprising: an interiorsupport-separator with an external radial and axial surface, extendingalong a longitudinal length of said communications cable, said interiorsupport-separator also having a central ring region, said central ringregion also extending along a longitudinal length of said interiorsupport-separator and said communications cable; said interiorsupport-separator comprising at least one symmetrical core with either adiamond-shaped or circular outer hollow ring region with an innerdiamond-shaped or hollow ring region with extending protrusions eachextending in a preferred separation from each of said other extendingprotrusions extending from said outer ring region.
 51. The highperformance communications cable of claim 50, wherein said central ringregion includes a hollow ring region acting as a duct for an air blownfiber (ABF) which is available for filling with optical fiber(s) orother conductor(s) with no extending protrusions.
 52. The highperformance communications cable of claim 51, wherein said interiorsupport-separator, and said central ring region shaped coresupport-separator sections comprising solid, partially solid, or foamedthermoplastic or thermosetting dielectric materials.
 53. The highperformance communications cable of claim 50, wherein said interiorsupport-separator, and said central ring region shaped coresupport-separator sections comprising solid, partially solid, or hollow,foamed organic or inorganic dielectric materials.
 54. The highperformance communications cable of claim 50, wherein channel walls ofsaid central ring region with extending protrusions are corrugatedincluding internal axial grooves separated by a sufficient distance suchthat individual conductors or conductor pairs maintain requiredelectrical integrity and such that said conductor or conductor pairs areforced against an edge of said grooves or sections of said channelwalls.
 55. The high performance communications cable of claim 50,wherein said interior support-separator comprises a corrugated orconvoluted external radial and axial surface extending along alongitudinal length of said communications cable, such that externalsurfaces of said symmetrical core with a central ring region includeexternal radial grooves also extending along said longitudinal length ofsaid interior support-separator such that said interiorsupport-separator can itself function as a cable jacket for saidcommunications cable.
 56. The high performance communications cable ofclaim 50, wherein said at least one symmetrical core with a central ringregion with said extending protrusions are singularly filled withindividual or paired metal or coaxial electrical transmitting conductorsor optical fiber light transmitting conductors, or filled with acombination of said individual or paired metal or optical conductorsalong said longitudinal length of said interior support-separator andsaid communications cable.
 57. The high performance communications cableof 56, wherein said metal conductors are copper with or without metallicshielding.
 58. The high performance communications cable of claim 56,wherein said metal conductors are aluminum with or without metallicshielding.
 59. The high performance communications cable of claim 50,wherein said communications cable comprises one or more axial strengthmembers wherein said axial strength members lie parallel to saidinterior support-separator inside a communications cable jacket orwithin said hollow ring region of said interior support-separator alongsaid longitudinal length of said interior support-separator and saidcommunications cable.
 60. The high performance communications cable ofclaim 1 comprising; an interior support-separator with an externalradial and axial surface, extending along a longitudinal length of saidcommunications cable, said interior support-separator also having acentral region, said central region also extending along a longitudinallength of said interior support-separator and said communications cable;said interior support-separator comprising a hollow four-petal daisyshaped arrangement with a central region, each hollow petal separated by90 degrees along an axial plane that extends along a complete length ofsaid communications cable allowing for individual or paired conductorsto be placed within said hollow petal.
 61. The high performancecommunications cable of claim 60, wherein said central region of saidfour-petal daisy shaped arrangement includes at least one hollow regionacting as a duct for an air blown fiber (ABF) which are available forfilling with optical fiber(s) or other conductor(s).
 62. The highperformance communications cable of claim 60, wherein said interiorsupport-separator comprises a hollow four-petal daisy shaped arrangementwith a central region, each said hollow petal separated by 90 degreesalong an axial plane that extends along a longitudinal length of saidcommunications cable allowing for individual or paired conductors to beplaced within each said hollow petal or within hollow sections ofotherwise solid petals.
 63. The high performance communications cable ofclaim 62, wherein said interior support-separator and said centralregion of said four-petal daisy shaped arrangement include a hollowregion acting as a duct for an air blown fiber (ABF) which is availablefor filling with optical fiber(s) or other conductor(s).
 64. The highperformance communications cable of claim 1 comprising: an interiorsupport-separator and an inner cross-like separator section with rifledsections extending outward into four quadrants away from said centralregion, said quadrants defined by 90 degree right angles formed by anintersection of extended cross-like rifled separator sections encasedwithin an outer insulated layer which is shaped in an identicalcross-like pattern as said extended cross-like rifled separator sectionsso that dimensions of said outer insulated layer forms a cross-likepattern larger than said inner cross-like separator section with rifledsections and functions as a skin for said inner cross-like separatorsection with rifled sections.
 65. The high performance communicationscable of claim 64, wherein said central region of an inner cross-likeseparator with said outer insulated layer includeing a hollow centralregion acting as a duct for an air blown fiber (ABF) which is availablefor filling with optical fiber or other conductors.
 66. The highperformance communications able of claim 1 comprising: an interiorsupport-separator with a cross-like separator section with zig-zagsections extending outward onto four quadrants away from said centralregion, said quadrants defined by 90 degree right angles formed by anintersection of said cross-like separator sections.
 67. The highperformance communications cable of claim 66, wherein said centralregion of said cross-like separator section with said zig-zag sectionsincludeing a hollow central region acting as a duct for an air blownfiber (ABF) which is available for filling with optical fiber or otherconductors.
 68. The high performance communications cable of claim 66,comprising; a cross-like separator section with zig-zag sections thathave sickle-like ends at each of said zig-zag sections extending outwardinto four quadrants away from said central region, said quadrantsdefined by 90 degree right angles formed by an intersection of extendedcross-like zig-zag separator sections with said sickle-like ends. 69.The high performance communications cable of claim 66, wherein saidcentral region of said cross-like separator sections with said zig-sagsections extended having said sickle-like ends including a hollowcentral region acting as a duct for an air blown fiber (ABF) which isavailable for filling with optical fiber(s) or other conductors.
 70. Thehigh performance communications cable as in claim 69, also providing aspecified lay length by implementing a twisting of said hollow centralregion thereby providing a lay length twist into said interiorsupport-separator prior to manufacturing a final communications cableassembly.